Update: Installation complete! Many thanks to all who responded with input and guidance. especially MusbJim with his great detailed ‘tutorial’ (@PanhandleBob - yes! Let’s archive that please!!).
My old VS rack and the new Leitz reproduction :
Hardware from MusbJim’s suggested shopping list - I added the plumbing supply lines (Wolfgang’s suggestion) to cover the carriage bolt threads (they fit perfectly over my 5/16” carriage bolts). In addition to fender washers I also added neoprene washers to ‘line’, or cushion, the fender washer’s contact with the fiberglass:
Before assembly I test fit the carriage bolts to determine and adjust rack height. It’s easy and simple to do this before the bolts are affixed to the rack. I had noticed from file pics and other resources that some installations had the rack frame almost flush to the grill, while others looked like the frame was ‘elevated’ by at least a couple of inches. I opted to sort of split the difference by installing my rack so that the the lower portion of the frame is a shade over an inch above the grill. This test fit was super helpful since the upper (forward) portion of the rain tray is shallower than the lower (aft) portion.
Carriage bolts secured to rack allow for an opportunity to test fit the rack itself. I was working with holes already drilled in the rain tray from my old VS rack installation and didn’t want to drill new holes if I could help it. Initially the new bolt pattern didn’t line up perfectly with the existing holes, but several gentle taps with a rubber mallet along the length of each bolt provided just the encouragement needed to get the bolts to slide into the existing holes. The nut seen on the bolt (lower pic) acts as a ‘stop’ and determines the height of the rack as the remaining length of exposed bolt slides into the mounting hole:
Satisfied with the height of the rack, and with all four corners adjusted, I carefully marked the bolt position and added the plumbing supply line (simply cut it to length) to cover the threads, using thread-lock on the nuts during reassembly to keep it all snug and secure:
Finally, I positioned fender washers (and the paired neoprene washers) under the grill on the top of the rain tray, carefully aligning them with the mounting holes. Using one of those extending magnetic ‘wands’ made it fairly easy to manipulate the washers into place without having to remove the grill.
From there, I simply (slowly, gently) dropped in the rack, guiding the bolts through the washers and down into the holes. All that was left was to add washers and nuts from below and tighten it all up snug while being careful not to over tighten. I ended up not needing nylon spacers under the lid.
Done, Baby!
I love the Reuter racks, definitely appreciate their historical authenticity, and also understand that the Leitz racks weren’t introduced until around 1960 (from MusbJim’s vast knowledge bank) but sourcing a Reuter in good condition was very expensive, and Sierra Madre had a 20% off sale that made an impulse buy of the ‘driver quality’ Leitz very easy. It’s a definite ‘upgrade’ from the stock VS rack in my humble opinion. Now on a quest for some nice leather luggage straps to complete the look!
Again, many thanks to all, and Happy Motoring!!!
- Brent