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My Traveller was literally a basket case when I bought it (stalled project, previous owner did the disassembly) - I'm having a hard time figuring out how the front panel attaches to the subframe.

The two large holes in the front panel align with the two holes in the subframe but I don't understand how a 3/8" bolt is supposed to not go through a ~1" hole and there is a 1/2" space between the front panel and the subframe.

I've tried looking through the build logs but have yet to find a good picture of this area. What am I missing? Is there a bushing or something that acts as a spacer?

Thanks!

The holes in the subframe are supposed to be 3/8", if they are 1" somebody has enlarged them. There should be no space between the front panel and the subframe. If here is a space it indicates the front panel was installed without the subframe being in place. This would not be the first time this has happened. You need to de-install the front panel and start over with the subfame bolted in place.

The subframe holes are 3/8" but the holes in the front panel are about 1". The front panel is new and hasn't been installed (did the previous owner buy the wrong panel?) I am using the forward edge of the inner fenders as a reference. I have the gap when this edge is touching the back side of the front panel.

Sounds like you have a '76 onwards front panel which used rubber mountings between the subframe and bodyshell. You can buy solid mounts to fix the problem or modify the front panel mountings to suit.
http://www.minispares.com/catalogues/cl ... x?3~21~206

Thanks - this is what I currently have.

Is there an easy way to confirm that this is a 76+ front panel?

The larger mounting hole and the two extra side light fixings are a clue, you'll also find the raised area for the sidelights is bigger in diameter than the early panels. What you have to remember is that you can't buy the exact replacement panels for the early cars, at best you have to buy a later panel and modify it, and it depends how far you want to go to match the original. M-Machine can supply a closer match to the original but it still won't be exactly correct.
The photo is an original panel, you can see how the mounting face is flush with the lower flange unlike yours which is moved forward the clear the rubber mount,.

Hi Bob, you have a pm. Cheers. Mark

that's 100% a 76 on front panel

you could use it if you fit a pair of the rubber pear mounts to it (or the solid alloy ones)

That picture answers everything Bob - thanks.

I made a 1/2" thick spacer and welded it to the panel's back side - seems to have done the trick.

Rich - I missed it the first time around but there is a barely legible part tag on the inside of the panel (faded from years of sitting around). I was able to make out "ALA8619" which according to Google is a 1976+ panel sold by Mini Spares.

I feel stupid for not seeing this sooner - thanks for the help guys!