Project Sammy 8

Some time ago I remember promising you we would be getting better protected from the elements. Well, finally I can reveal Sammy’s new fast top hood. Not too amazing in itself perhaps, but I took the opportunity to go to MLC Monsoon Ltd.’s Lower Dicker factory to see how it was made and now dear reader I shall enlighten you to the dark arts of hood manufacturing.

I have been through some hoods over the years and I have no qualms about personally recommending the Monsoon range. Their materials, processes and attention to detail are second to none, as are their workforce of crafts men and women. If you want a hood that fits and doesn’t fall apart after a couple of years (and let me assure you, there is definitely some crap out there that will) then look no further.

I met up with Tony Pollard, the company’s Administration Manager one cold, wet and windy winters afternoon and he gave me a tour of the premises. The first thing that strikes you is the light, airy, friendly feel of the place, not like your stereotypical factory unit at all. And clean, not only is the place virtually spotless, but there isn’t a trace of the heaps of surplus material lying about that you might expect.

As Tony is explaining the various areas of the workshop a material delivery fortuitously arrives and gives me the opportunity to see the entire process of making a hood, from the time the material comes through the roller shutters, until it is finally boxed up and sent out. The rolls of material are stored near to the roller doors ready to be placed on the first of the machines that lays it flat and cuts it into uniform, manageable sized, sheets.

The next step is to check each piece of material by hand to ensure that any possible flaws do not pass through into the final hood. From here the sheet of material passes along the table to be hand cut from time served patterns for each required section (i.e. top, sides and back) before having the windows welded into place. An interesting feature here, the windows are actually welded onto the material and the excess is left in place, not only protecting one side of the clear plastic from damage, but also minimising any distortion to the panel during the following manufacturing process, the excess material finally being removed when the hood is completed.

All of the windows and seams are high frequency welded and all stitching is carried out using a waterproof Polyfil cotton. As Tony helpfully explained in layman’s terms, this means that the stitching absorbs a certain amount of moisture when wet and expands to fill the stitch holes, effectively sealing the last remaining area for any possible ingress of water. So basically whatever the weather (or you) might throw at it you can rest assured; it won’t be coming in.

Another surprise in the hood making procedure is the fitting of the poppers. These are all installed whilst the hood is fitted to a vehicle body. Stored out the back of the factory is, what might at first glance appear to be a mini 4x4 graveyard, in the form of several rear shells. These are used as patterns to test fit every single hood, install the fixtures and fittings and final finishing. This ensures that whatever minor differences occur when the hood is put together every one will fit perfectly, as the fittings are actually installed to fit the vehicle body.

Whilst we are outside Tony takes the opportunity to show me the metalwork shop. As with every stage of the manufacturing of their soft tops Monsoon ensure absolute quality control of the associated metalwork for their foldaway style hoods by making as much as possible in-house. Very little is bought in other than the raw materials in the form of the fabric and steel tubes and plates, virtually everything else is built in house which is obviously by far the best way to ensure quality control; and everything you see at Monsoon reeks of quality, even down to the blushing pink overalls!

Apart from the fast back top for the SJ/Samurai series Monsoon also supply both standard and bikini tops for both the SJ and Vitara. They also build the famous foldaway hood for the Vitara, Grand Vitara and Jimny. These are the ultimate in luxury, no more messing about in the rain trying to get the hood back on in one of those sudden summer downpours we love so much, just a quick pull and a couple of poppers and you’re in the dry; before the rain stops again!

Whilst my interest is obviously mainly Suzukis, Monsoon have no such limitations, supplying hoods for the Daihatsu Sportrak and Asia Rocsta and tonneau covers for the Ford Ranger, Nissan D21/D22/D23, Nissan F22/F23, Nissan Navara Double Cab, Toyota Hilux Single & Double Cab and Vauxhall Brava. Monsoon have also been suppliers of Tonneau Covers to major Japanese vehicle importers for over 12 years including Nissan GB, Mitsubishi Motors, Isuzu Europe and Toyota Europe to name but a few.

The firm itself was originally founded in 1980 as Mobile & Leisure Concepts designing and manufacturing original equipment accessories for some of the leading Japanese vehicle importers in Europe, a side of the business that is still going strong nearly 25 years later. On the domestic front they are the market leader supplying, as they do, in excess of 5,000 hoods a year to the general public and are still expecting to expand even further into Europe in the near future. I think you’ll agree their pedigree speaks for itself. 

I could hardly wait to open the box and fit the new hood to Sammy, and if you are likewise excited by the idea of revitalising your beloved with a new top (no, your truck, stupid) then you can have one tomorrow! Monsoon hold substantial stocks and so long as your order is received before 15:30 they offer a next day delivery service. So, if you can’t wait, you don’t have to!

Sammy’s hood looks wonderful, even in the box, and has notched up several envious glances even before it’s fitted. On the truck it’s something else. It really shows up how shabby Sammy has become and I’ll have to get my finger out and tidy her up if she is to be worthy of driving round with her nice white hood and smoked windows. I can hardly bear to get it dirty!

There is just one down point, (hey! It wouldn’t be a Richardson article without there being at least one downer!) and that is absolutely nothing to do with the hood in any way, but I will warn you here in case you are intending to do the sill modification I have done to Sammy. If you are removing the sills from a soft top do not rely on the chassis to hold the body in alignment. I did and after fitting the new sills when I opened the doors the body popped forward ever so slightly.

Whilst the movement in the floor is miniscule, over the length of the front bulkhead and windscreen this equates to about 12mm at the top where the hood fits. Yes, you’ve guessed it! It may not sound like much, but like I said, these hoods are made to fit; perfectly. So as Sammy is half an inch longer than she should be the hood is going to be a real struggle to get on. It’s not insurmountable because by its very nature the upper parts of the screen etc can be adjusted but it would be preferable not to have to mess about with it in the first place so be warned and brace the body before removing the sills.

With the hood finally installed it is a revelation, no more flapping material, no more ponding on top when it rains and no more drips on the head either. But the most obvious major difference I have noticed to date is the poppers that hold the flaps that encircle the door lintels instead of that crappy Velcro tab system that always looked like it would fly open, exposing you to the elements, when the wind got up.

If you think you would like to emulate Sammy with your truck then hand those nice people at Monsoon about £170 and you can. This price includes VAT and delivery and those snazzy smoked windows at no extra cost.

Finally, if this has whetted your appetite, or even if you just want to see what I have described for yourself, simply contact Monsoon to arrange a visit. The factory is open to any potential customer wishing to have a look round and I can personally vouch for their hospitality. You can get hold of Monsoon at the following address or look them up on the net at www.monsoon4x4.co.uk.

MLC Monsoon Limited

Northfield Business Park, London Road, 

Lower Dicker, East Sussex, BN27 4BZ

Tel: 01323 440422    Fax: 01323 845705