the jamaican - FIBERFAB.US

THE
JAMAICAN
The JAMAICAN is Fibeifab's newest entry in the
field o f ultra-modern automotive body design. The
aged rusted-out, leaky bodies it is designed to
replace. Comfortable and weathertight, the JA-
JAMAICAN is designed to capture i n fiberglass
the very latest trends in sports a n d GT Styling smoother I ~ n e s ;uncluttered, graceful contours; all
combined with the look of power.
M A I C A N is rust and corrosion proof making it a
The J A M A I C A N 1s s ~ r i t a b l efor use o n a number of
practical as well as a beautiful conversion.
N o t only does the design of the JAMAICAN incorporate the ultimate i n styling a n d utmost in
comfort it also gives considerable a t t e n t ~ o n to
readily available sports c3r chassis. The use o f
d r ~ v e rs<ifety - all the JAPVIAICAN window opent h e exist,ng ,netal
f l o o r panels o f t h e
various chassis, coupled w ~ t hthe bull[-in paneling
lngs are designed to accept readily available
of the JAMAICAFI b o d y , provides easy ~ n s t ~ i l l a t ~ o n crulomotlve s ~ f e t y glass, ~ n c l u d i n g roll u p side
on the PVIGA, A u s t ~ n He.iley J. A u s t ~ n Ht:L~l~,y Cj
T r t l ~ l n p hT R - 3 TI?-4 ,incl \/LV
w ~ n d o w s , p r o i ~ l s l o n for ~ r i t e g r a l roll b a r ' ,
rein-
fr?r(:r>ll ~ ~ ~ ~ ; c l ~ ; ~
lip
t ~t :l In~~i n q
The JAPVIAICAN CiT c o u p e j t y l l n ~ j~ ; r , ~ f t c tIn
~ l t~t,l?r-
FI B E R FA B
2 3 6 5 LAFAYETTE
sA,-ra
=LA-1,
c n L , F .ssoso
r
Here are your Jamaican M o u n t i n g I n s t r u c t i o n s .
include a l l the drawings,
require to complete
parts lists, etc.
your car.
However,
They
you w i l l
before you
peruse the plans l e t ' s consider the tools you'll need
and a few sources of c h a s s i s .
A l l of our f a c t o r y cars,
instructions,
l i k e the ones shown i n these
are b u i l t u s i n g no more t h a n the ordinary
home workshop inventory of tools.
a minimum "Jamaican Workshop",
1. 1 / 4 " e l e c t r i c d r i l l
2.
3.
4.
5.
6.
7.
8.
9.
W e recommend,as
the following:
1 / 8 " , 1 / 4 " , 3 / 8 " ( w i t h 1/4"shank) d r i l l b i t s
One s e t o f w o o d w o r k i n g h o l e s a w s
I<eyhole saw or e l e c t r i c saber saw
M e d i u m b l a d e standard a n d phillips s c r e w d r i v e r
3 / 8 " , 1/2",9/16t1 s o c k e t s , wrenches,etc.
Straight edge
Steel tape
Assorted rasps
W i t h regards to the procurement of a chassis
you're not already driving i t
i.41~ h
--
if
--
a \ ~ f~o!u n d t h e a u t o w r e c k i n g
yards t o be a good
source of chassis--locally we have a directory called
a P A R T S LOCATOR which l i s t s the various years and
m a k e s a v a i l a b l e t h r o ~ r g h o u to u r t e r r i t o r y .
check to see i f an
your locale.
equivalent guide
You should
is available
in
Another source i s your insurance agent
riotify you i f he processes any
involving the chassis
"
auto parts"
ask him to
"total wreck"
- type you're after.
check the c l a s s i f i e d ads i n your
the
--
headings
--
claims
Finally,
local papers u n d e r
many times
chassis is l i s t e d by an owner before he
a
usable
sells it t o
a dismantler.
Now on t o the d e t a i l s . .
.... .. .
Note: These instructions represent the principal corr~positionof the
total Jamaican Mounting Instructions Package. Some ver detailed
material is withheld and w i l l be sent with your body. In i s manner
we can always introduce up-to-m inute changes into the instructions---changes which occur inevitably as a result of our continuing program of product refinement and improvement.
X
T H E COST OF THESE INSTRUCTIONS
W I L L B E REFLlNDED ON RECEIPT OF
YOUR F I R S T ORDER.
1
1.
CHASSIS
Required:
Frame and suspension (incl. hubs)
Engine (unless considering engine swap)
Transmission, propellor shaft, rear axle
Steering assembl y, brake system
Pedal Assembly, (clutch, brake, throttl e)
Some inner panelling (see figure 2 )
Gas tank, Trans. & shaft tunnel covers
Floor boards (MGA), radiator
Desirable:
Original wiring
Heater
Instruments
Wheels and tires
2..
J A M A I C A N DOOR H A R D W A R E
Door Hinges two sets of hinges are required
Austin Healey, MGA1TR3,TR4
-
Windows
-
Ford CODB 6 4 2 2 8 0 0 A rt. tp.
Ford CODB 6 4 2 2 7 0 1 A If. tp.
VW143 8 4 5 201A& 202A
(glass) 1 9 6 0 - 6 3 Karmann Ghia
(also 6 0 - 6 3 Karmann Ghia)
551B. 552B. 571A.565A
~ ~ 1 4 1 8 53 0 71 ~ & 5 0 2 ~
Standard w/upholstery k i t or i s
available from Fiberfab
VW 1 4 3 8 4 5 2 1 1 A & 2 1 2
VW 1 4 3 853 3 3 7 A & 3 3 8 A
Somaca B - 6 0 5 (4ea.l
( 6 1 - 6 3 GM cars)
VW 1 4 3 853 5 1 6 A (2ea.l
left and right door windows
Regulator mechanisms
Weather stripping
- one windlace k i t
Window opening weather stripping
Matherstripping chrome trim
Outside and inside wiper rubber
Outside wiper chrome trim
Door Latches Option 1 (for handleless key
only operation):
DOOR L A T C H E S
-
Ford
Ford
Ford
Ford
Ford
Door lock cylinder
Striker Studs
-
Door Latches Option 2 (~j$.,hgd!es!Use standard hardware: Latches, Kandles,
and striker studs.
3.
4.
Karmann Ghia
WINDSHIELD
Safetv Glass windshield (included
w ~ t hr n e u e i u x e K I L ;
Rubber Molding
Chrome Molding and retainor c l i p s
REAR WllVDOW
{a:';
Glass Windshield (included
the Deluxe Kit)
Rubber Molding
Chrome Molding
C45Z- 6321813-C
C45Z- 6321812-C
C50Z-6221984-A1
C20B-6220008
C20B-6220009
1 9 6 3 - 6 6 Corvette Stingray
Chev.
Chev.
Chev.
Chev.
Chev.
Chev.
I
3844049
3841251
3841255
3859044
3859045
3843939
Porsche
Porsche
Porsche
Porsche
Porsche
Porsche
Porsche
(lea.
(lea.)
(2ea.l
(2ea.l
(20ea.l
901 545 10120
9 1 2 Rear Window
901 545 911 20
9 0 1 5 4 5 912 20
9 1 2 Rear Window
644 5 4 1 9 2 1 0 6
9 1 2 Rear Window
5.
HOOD
H e a d I i g h t s : high b e a d l o w beam combination
units (identified by 3-prong connector) with
mounting brackets and chrome bulb retaining
ring, such as the sealed beam units standard
on Austin-Healey MGA and TR.
G r i I l : Any g r i l l oC our choice f i t t i n g an
opening measuring " x 4 4 " overal I. Suggested
g r i l l include egg-crate (Camaro), horizontal bar,
and expanded metal (available at most hardware
stores)
P a r k / t u r n i n d i c a t o r l i g h t s : select
dual-element 1 2 v bulb units compatible with
your g r i l l selection. The lights standard on
your chassis w i l l probably suffice.
Hood Latch:
Option 1: Side Mount
Option 2: Center Mount
5
6.
7.
OTHER BODY HARDWARE
T a i l l i g h t s : A n y f l a t p a n e l mountedtail
light units of not more than 7" high or 8"
wide may be utilized.
L i c e n s e p l a t e l i g h t / b r a c k e t : Combination holder and light available at most a u t o
supply stores.
Gas tank f i l l e r cap:
Standard AustinHealey, MGA or TR cap or chrome flip-top
cap available from Fiberfab.
INSTRUMENTS
I f the stock gauges are not functioning or are
not avail able, Fiberfab can supply replacements
out of the extensive Stewart-Warner line. The
following items may be ordered from your local
Stewart-Warner dealer or directly from us..
...
Fuel level gauge
Fuel level sender
Instal lation k i t
Triumph Spitfire
Austin-Healey or MGA
Austin-Healey, MGA,or TR
STEWART-WARNER NO.
301-AW
385-C
366-LP
Water temperature gauge
Temperature sender
O i l pressure gauge
Pressure sender
Ammeter
Speedometer (16 0 M PHI
Other Optional Instruments
O i l temperature gauge
Temperature sender
Tachometer
Tachometer sender
311-CF
See Water Temperature
I
548 Baldwln Street
Brldgevllle. Pennsylvania 15017
Phone 472 221-6200
JAMAICAN SERIES PRICE L I S T
JAMAICAN
S E R I E S B A S I C BODY K I T S :
A
I
A
JAMAICAN
JAMAICAN
II
!I-V8
EFFECTIVE 7/1/76
B A S I C BODY K I T S F O R T R 3 , T R 4 , T . R b A , T R 6 , T R Z S O ,
A U S T I N HEALEY 3 0 0 0 .
B A S I C BODY K I T F O R VW OR K A R M A N N G H I A .
F R A M E * A N 0 B A S l C BODY K I T FOR FRONT MOUNTED v 8 .
MGA,
* T H E J A M A I C A N I I - V 8 FRAME K I T I S A S U P E R S O P H I S T I C A T E D I N D E P E N D E N T SUSPENS I O N A N D POWER T R A I N .
T H E J A M A I C A N l l - V 8 F R A M E I S A L A D D E R F R A M E C O N S T R U C T E D O F 5" X 2 " X . I 2 0
STEEL T U B I N G , H E L I A R C WELDED TOGETHER I N A S T A B I L I Z I N G J I G .
A SPECIAL
F L O O R P A N I N T H E J A M A I C A N 1 1 - V 8 BODY L O C K S T H E B O D Y I N P L A C E ON T H E F R A M E .
T H E F R A H E I S E N G I N E E R E D T O A C C E P T A S M A L L B L O C K C H E V Y V 8 FORWARD MOUNTED.
C O U P L E D TO A C O M P A T I B L E S T A N D A R D OR A U T O M A T I C T R A N S M I S S I O N .
THE FRONT
T H E T H I R D MEMBER I S C O R V E T T E ( ' 6 3
S U S P E N S I O N I S C O R V A I R ( ' 6 6 OR N E W E R ) ,
OR N E W E R ) ,
A N 0 T H E R E A R S U S P E N S I O N I S C O R V A I R ( ' 6 6 OR N E W E R ) .
CORVAIR
R E C I R C U L A T I N G B A L L T Y P E OR P I N T O R A C K h P I N I O N T Y P E S T E E R I N G MAY BE U S E D .
T H E NEWEST J A M A I C A N l l - V 8 K I T U T I L I Z E S T H E CAHARO FRONT SUBFRAME A 9 D T H E
C H E V E L L E REAR A X L E ASSEMBLY.
J A M A I C A N S E R I E S B A S I C BODY K l T S
1.
2.
3.
4.
5.
6.
7.
. 8.
9.
INCLUDE:
M A I N BODY W I T H I N N E R P A N E L S .
FORWARD N O S E S E C T I O N ( O N E - P I E C E T I L T C O N F I G U R A T I O N )
FOR J A M A I C A N I K I T S ONLY.
FORWARD N O S E S E C T I O N A N D S E P A R A T E H O O D F O R J A M A I C A N I I A N 0 l l - V 8 K l T S O N L Y .
E N G I N E ACCESS/TRUNK L I D FOR J A M A I C A N I I AND l l - V 8 K I T S ONLY.
ONE P A I R DOORS.
ONE P A I R F I B E R G L A S S GT SEAT SHELLS (NOT U P H O L S T E R E D ) .
E A S Y R I D E R S E A T S H E L L S W l T H H E A D R E S T A R E O P T I O N A L AND $ 3 0 . 0 0 A D D I T I O N A L .
ONE D A S H P I E C E .
F R A M E K I T FOR J A M A I C A N l l - V 8 K I T O N L Y .
ONE F I B E R G L A S S T R A N S M I S S I O N C O N S O L E - C O V E R F O R J A M A I C A N 1 1 - V 8 K I T O N L Y .
ASSEMBLY MANUAL.
(MAY BE ORDERED I N ADVANCE FOR $10.00.)
SPECIFY CHASSIS.
JAMAICAN SERIES OPTIONS:
VDO C O C K P I T G A U G E S
VDO C O C K P I T
1 2 VOLT ONLY:
GAUGES FOR J A M A I C A N
ll-V8
I N T E R I O R UPHOLSTERY, B L A C K ONLY.
SEAT COVERS, BLACK ONLY, PAIR.
EASY R I D E R S E A T COVERS, B L A C K ONLY,
ONLY:
SPEEDOMETER
TACHOMETER
AMMETER
F U E L GAUGE
O I L T E M P E R A T U R E GAUGE
O I L TEMPERATURE SENDER
SPEEDOMETER
TACHOMETER
AMMETER
F U E L GAUGE
O I L P R E S S U R E GAUGE
O I L PRESSURE SENDER
W A T E R T E M P E R A T U R E GAUGE
WATER T E M P E R A T U R E SENDER
cr
PAIR.
T H E J A M A I C A N S E R I E S B O D Y K l T S A R E NOW O F F E R E O I N P R E - A S S E M B L E D F O R M .
T H E BODY I S T O T A L L Y A S S E M B L E D .
J U S T MOUNT TO Y O U R C H A S S I S .
c o n P u l E FRon PRICE LIST ITEMS DESIRED.
ADO L A B O R C H A R G E O F $ 1 2 0 0 . 0 0 F O R J A M A I C A N I A N 0 l l K I T S , $ 1 5 0 0 . 0 0 F O R J A M A I C A N
11-V8
KIT.
J A M A l CAN
SERIES
DELUXE
PAK
(OPTIONAL
ITEMS) :
WINDSHIELD CLASS
CORVETTE ' 6 3 - ' 6 7
WINDSHIELD REVEAL MOLDING
CORVETTE ' 6 4 - ' 6 7
WINDSHIELD POLY TAPE
WINDSHIELD REVEAL C L I P S
REAR GLASS CLEAR
PORSCHE 9 1 1 - 9 1 2
REAR C L A S Z U A A ~ C ~
REAR GLASS REVEAL MOLDING
S I D E CLASS
KARMANN G H l A HARDTOP ' 6 1 - ' 7 4
S I D E GLASS C A R R I E R CHANNEL
KARMANN G H l A HARDTOP l 6 1 - ' 7 4
S I D E GLASS C A R R I E R GASKET
KARMANN G H l A HARDTOP ' 6 1 - ' 7 4
S I D E GLASS REGULATOR
KARMANN G H l A HARDTOP ' 6 1 - ' 7 4
S I D E CLASS WINDOW G U I D E TRACK
KARMANN G H l A HARDTOP ' 6 1 - ' 7 4
S I D E GLASS HOLDING EXTRUSION
S I D E GLASS MOLDING EXTRUSION WEATHERSTRIP
S I D E GLASS WEATHERSTRIP INNER
S I D E GLASS WEATHERSTRIP OUTER
DOOR H I N G E S L E F T
MUSTANG ' 6 5 - ' 6 7
OR P I N T O
DOOR H I N G E S R I G H T
M U S T A N G ' 6 5 - ' 6 7 OR P I N T O
OUTSIDE BAT HANDLE, LATCH & CABLE ACTUATOR
WINOLACE
DOORWAY S U R R O U N D
H E A D L lG U T
FRONT TURN S I G N A L
T A I L LIGHT
I N D I C A T O R DASH L I G H T
CHROME GAS CAP C O V E R
0 1 M M E R SUI T C H
ST BAT HANDLE SWITCH
I G N I T I O N SWITCH WITH KEYS
HEADLIGHT BAT HANDLE SWITCH
I N S I D E REAR V I E W H I R R O R
WALNUT S T E E R I N G WHEEL
WIRING HARNESS
DEFOGGER
DEFROSTER
FENDER MOUNT MIRROR
BLACK PRIHED
DOOR L A T C H H A N D L E I N S I D E , E U R O P E A N S T Y L E
DOOR W I N D O W H A N D L E I N S I D E , E U R O P E A N S T Y L E
W I N D S H I E L O W I P E R A S S E M B L Y . COHPLETE W I T H ARMS 6 B L A D E S
-
-
JAMAICAN
-
SERIES
1 REP.
1 REP.
1 REP.
1 SET
I REP.
1 REQ.
1 REQ.
2 REQ.
2 REQ.
2 REQ.
2 REQ.
2 REQ.
2 REQ.
2 REQ.
2 REP.
2 REQ.
1 SET
1 SET
2 REQ.
2 REQ.
2 REQ.
2 REP.
2 R E Q .
3 REP.
I REP.
1 REQ.
2 REP.
1 REP.
I REQ.
1 REQ.
1 REP.
1 REQ.
1 REQ.
2 REP.
2 REQ.
2 REQ.
I REQ.
ACCESSORIES:
O I L PRESSURE GAUGE 7 0 d
O I L PRESSURE GAUGE SENDER
FUEL TANK FLOAT U N l T
QUARTZ CLOCK
FOUR-WAY F L A S H E R S
L I C E N S E P L A T E BRACKET AND L I G H T
CONSOLE
EUROPEAN S T Y L I N G
ROADRUNNER S T E E R I N G UHEEL
F O R M U L A GT S T E E R I N G U H E E L
LEATHER COVERED
SEAT ADJUSTERS, 5" T R A V E L , P A l R
QUICKSHIFT K I T
CUSTOM SI1I F T E R ' 6 8 - ' 7 4 V U
CUSTOM S H I F T E R ' 5 6 - ! 6 7
VU
PEDAL AND ACCELERATOR COVER K I T
O I L COOLER AND F I L T E R U N l T
H I GH P E R F O R M A N C E A I R C L E A N E R
CHROME
F E N D E R MOUNT M I R R O R
HEADLIGHT COVERS, P A I R
GT S T Y L E FRONT RUMPER
GT S T Y L E H E A R OIJMPER
HEADER/DUAL M l l r F L E R COMBINAT I Otl
DECALS, BLACK LETTERING, P A l R
M E D A L L I O N , HOUtdU P E W T E R
-
-
FOAM
-
CURB UE1611T:
JAMAlC;lN
1 ,
16006,
JAMAICAN
ll,
1475#,
JAMAICAN
I I - v ~ ,2 1 0 0 6
$ 98.00
35.94
9.00
2.00
146.25
35.63
47.50
44.00
5.00
2.00
28.00
29.10
7.40
9.40
5.25
6.25
19.95
19.95
21.56
15.00
24.30
5.67
23.20
2.67
11.01
2.74
3.97
8.00
3-97
10.58
39.95
45.00
39.50
9.02
6.65
7.35
89.95
EA.
EA.
EA.
EA.
€A.
En.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
€A.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
EA.
L
KIT #I
- STANDARD
JAMAICAN KIT INCLUDES:
1 ) JAMAICAN body
2) Front hood hinges (prelaminated into body)
3) Complete inner panels (to mount body)
4) Headlight indents
5) Dashboard
6) Recessed license plate holder
KIT #2
I
7)
8)
9)
10)
11)
Wide, fully flanged doorsills
Rear window surround flange
Windshield surround flange
Metal reinforcing inside windshield area
Side and front air scoops
12) Mounting instruction booklet
- DELUXE JAMAICAN KIT, includes everything in KIT #1,
1 ) Safety glass windshield
2) Door-inner panels for roll-up mechanism
PLUS:
3) Rear safety glass window
4) Choice of GT, Classic or Lotus-type fiberglass
seat shells
Complete mounting and chassrs prepsratron instructions are included with each body order.
Should you wish a copy prior to purchasing your body, the mounting booklet is available for
$5.00 refundable with order.
JAMAICAN PRICE LIST
JAMAICAN
JAMAICAN
JAMAICAN
JAtvlAICAbl
Kit .?I, St,jndclrd
Klt s:?,
Deluxe
Deluxe Upholstery Kit ( B l k )
P l e x ~ q l ~ ~Hsesa r l l ~ f l h Covtlrs
t
The following accessories included with the Deluxe K i t are also available separately:
$795.00
895.00
195 00
30.00
1
T A B L E OF CONTENTS
CONSTRUCTION M A T E R I A L S
--
T o o l s and S u p p l i e s
W H A T TO L O O K FOR W H E N ACQUIRING A W R E C K E D
V E H I C L E : MG, T R , A U S T I N H E A L E Y
PREPARING THE CHASSIS
--
What goes? What stays?
IVIOUIVTING T H E J A M A I C A N B O D Y
I N S T A L L I N G THE WINDOWS AND WINDSHIELD
WIRING AND INSTRUMENTS
UPHOLSTERY
SANDING,
V-8
lo.
--
Interior
Finish
PRIMING AND PAINTING
POWER O P T I O N
JAMAICAN/VOLKSWAGEN
--
Exterior Finish
INTRODUCTION
T h e f o l l o w i n g p a g e s c o n t a i n i n s t r u c t i o n s f o r a s s e m b l i n g t h e 1968 JAMAICAN.
These instructions are intended to cover every phase of preparation,
and f i n i s h i n g
required to bring
your car
-
assembly
b u i l d i n g project to a successful
con-
clusion.
T o meet the demands o f the many p e o p l e who prefer tlie d r i v i n g " f e e l " and
e x t e r n a l a p p e a r a n c e o f a f r o n t - e n g i n e d s p o r t s c a r , F i b e r f a b c r e a t e d t h e JAMAICAN.
D u r i n g t h p d e v ~ l o p m e n to f t h e J A M A I C A N d e + i g n ,
it
e..4
r c l l i::d
t l i ~ :zzrtain
u n i b o d y c a r s s u c h a s t l i e Austin-Healey S p r i t e a n d M G B w e r e n o t s u i t a b l e v e h i c l e s
f o r a "body swap".
I n other words, removal o f tlie o r i g i n a l metal body removed
t o o much s t r u c t u r a l r i g i d i t y .
Nevertheless, e l i m i n a t i o n of the unibody cars s t i l l
l e f t t h r e e v e r y p o p u l a r f r o n t - e n g i n e d s p o r t s c a r s t o be c o n s i d e r e d
A U S T I N - H E A L E Y , MGA, and T R I U M P H .
W h e n y o u o r d e r y o u r JAMAICAN k i t ,
you plan to mount it,
inner
------------
you can s p e c i f y the c h a s s i s on w h i c h
s o t h a t w h e n y o u r JAMAICAN b o d y i s p r o d u c e d ,
for mounting are laminated i n t o the body--thus
c i s e l y on j u s t the type of car you are converting.
the proper
the body f i t s
pre-
1.
CONSTRUCTION M A T E R I A L S
The typical inventory of tools found in most home garages or basements w i l l probably more than
few tools are absolutely essential to the conversuffice to complete your JAMAICAN. In reality, very s ion.
The following breakdown of tools i s based on Fiberfab factory ex erience.. Items that are considered essential are listed. Another l i s t is also ~ r o v i d e dof items whic are q u ~ t ehelpful and serve
to make certain construction tasks significant1 y easier.
f:
HAND TOOLS
Essential
-5/16",
3/8", 7 / 1 6 " , 1/2", 9 / 1 6 " , 5 / 8 " sockets
-31.6'. L r ~ v eRachet Handle
-Standard
screw-driver
medium blade
---Phillips screw-driver -- medium blade
Straight-edge
-- 3 / 8 "
Drive
--
--
6
Drive
3" and 6 extensions
7/16", 1/2", / 1 6 " combination (open-end and box-end wrenches)
" ~ o p l 'rivet gun
home workshop variety
-Steel
rule (72")
+ire-terminal
crimping tool
-Hacksaw
Knife
Assorted rasps, files, drills and taps
-Set
of wood-working hole-saws
-3/8"
-3/811
--
-
POWER TOOLS
Essential
-Electric
drill
1 / 4 " capacity
Helpful
Electric drill
1 / 2 " capacity
Sabre saw
Rotary sander/grinder
Hydraulic floor-jack and jack stands
--
--
CONSTRUCTION MATERIALS
Essential
Assorted .machine bolts and nuts; 1/4",5/16" and 3/8"; with washers and locking washers
Assorted sheet metal screws
Sandpaper
Silicone seal (common types are Rubber Sealant by the Macklenburg-Duncan Company of
Oklahoma City, Dow-Corning DC 7 5 0 , and General Electric)
typical is Somaca#9103*
But I tape (windshield installation kit)
2 0 8 ' - 3 0 0 ' # Z 6 AWG wire; 1 0 0 ' - 1 5 0 ' # 1 0 AWG wire (if chassis re-wiring required)
Primer, paint, etc.
Car seam sealer, 1 tube -- typical is 3W # 1 9 1 5 - 5 2 0 9
Helpful
Epoxy adhesive k i t ( high-grade epoxy, *body
filler type)
Epoxy putty/filler
Crimp-on wire terminals
Assorted "pop" rivets
--
*
*
Somaca-Western, 8 5 2 Aldo Ave., Santa Clara, Calif. SOMMER AND M A C A , 5 5 0 1 W.Ogden Ave.,
Chicago, Illinois
3 M is the trademark of Minnesota Mining and Manufacturing
2 . WHAT TO LOOK FOR WHEN ACQUIRING A W R E C K E D V E H I C L E
Many persons purchasing a J A M A I C A N body w i s l i to replace the travelworli or weatllered "skin" of tlre
vellicle they already own and are currently driving. Other builders plan to acquire a wrecked Austin Healey,
M G A or TR from a salvage yard and refurbisli t h i s "outcast" w i t h a new J A M A I C A N body and perhaps some
new nlechanical parts. In either instance, t h i s brief section should be of interest to a l l prospective builders.
I n most areas o f the Uriited States, a t l e a s t three approaches to obtaining a suitable, salvageable
sports car are available. The f i r s t approach i s to contact the local dealer i r ~tfie vehicle of interest. He
may have been asked to b i d on insurance work and w i l l kriow tlie a v a i l a b i l i t y arid locatiolr of wrecked vehicles.
Tlie second approacli is to c a l l several automobile irisurallce conlpanies arid ask about ariy recent wrecks
they have declared to be "totals"
marly tirnes i f the car i s earlier than 1 9 6 0 atid the body damage i s moderate to extensive, the car w i l l be "totalled" even thougll under i t s rumpled s k i n i s a m e m i c a 1 "jewel".
--
Tlie third and most obvious aooroach i s t o c a l l the local salvaqe/wrecking yards -- ~ s y c i a l l ythose advertising a foreign car section. Some areas ot the U.5.; tor example, the San F r a r ~ c i s c oBay Area wliere
Fiberfab i s located; have publications appearirig weekly or monthly w l ~ i c l il i s t a l l wrecked vehicles and
their location. The publicatiori we use is:
THE PARTS LOCATOR
1 6 9 6 Wastiirigton Avenue
San Leandro, California
lrrfortnation concerning similar publications ill other l o c a l i t i e s may be forthcornirig from tlie above address,
upon request.
When a seemingly suitable wreck i s f i n a l l y located, look i t over c l o s e l y i n person, not via photographs.
Don't l e t a mangled body dismay you or a clean-looking body fool you. Remember, you are interested primarily
i n the frame, drive-line, suspension a l l d engine
broken doors, ripped seats, sliattered glass, etc., are
o f not consequence.
--
Items to be checked are:
1. CONDITION OF ENGINE
--
valve cover not crrrslred, carburetors intact, exhaust manifold not
try to get some kind of
torn loose, pan secure and not leakilrg, radiator free of punctures, etc.
guarantee that the engine i s i n rurining condition.
--
2. CONDITION O F SUSPENSION
(front suspension) unbent, etc.
-- a l l axles rotate,
3. CONDITION O F D R I V E - L I N E
--
4. CONDITION OF T H E F R A M E
--
steering linkage i s not bent or broken, A-frames
w i t t i one rear wheel blocked from rotating, make sure the other
rear wheel turns reasonable freely when the gearbox i s i n neutral and does riot turn a t a l l when any
gear i s selected (assuming, of course, that an engine i s i n place i n the veliicle).
using a steel tape, measure the squareness of the frame; ie.,
check fore and a f t dimension between the wheel centers on both sides (the "wlleelbase")
are
they i d e n t i c a l ? Look under the car and assure yourself that none of tlie frame members are crushed
or bent.
--
I n addition, try to get as many pieces of a u x i l i a r y equipment as possible a t the time you buy the "outcast"
---items such as windshield wiper motors, instruments, etc., w i l l probably be cheaper i n a "package deal"
than i f you return later to purchase them separately.
A s an a i d to acquiring a usable wreck and estimating i t s worth, some v i t a l s t a t i s t i c s are presented below:
AUSTIN-HEALEY
The A u s t i n Motor Company of Birmirrgliarn, England started building the Austin-Healey 1 0 0 sports car
i n 1952. The Austin-Healey 1 0 0 used the 2.6 liter, four-cylinder A u s t i n A 9 0 e ~ ~ g i l l e .Subsequent versions were the l O O M and 1 0 0 s ; both aimed a t competition events. The 1 0 0 s errgirie developed 132 BH P
and had disc brakes.
Next i n the A u s t i n - M a l e y evolution was the 1 0 0 - 6 usirig a BMC, 2 . 6 liter, s i x cylirider erigine. Some
of the 1 0 0 - 6 models were produced w i t h a s i x - p o r t l i e a d to obtain higher performarlce than the standard 1 0 0 - 6
eligine output of 1 0 2 BHP. 111 1959, a 3 l i t e r s i x cylinder engine was irltroduced i n tlre Austili-Healey 3 0 0 0 .
T l i e 3 l i t e r engine was available for a brief period ( 1 9 6 1 - 1 9 6 2 ) i n a 3-carburetor version wliich proved quite
d i f f i c u l t to keep i n tune. Tlie Austin-Healey 3 0 0 0 had d i s c brakes (front) arid wire wheel options. Tlle
wheelbase i s 9 2 inches.
MG
-
As early as 1 9 3 6 , the MG Company (now located at Abingdon, England), produced a vehicle suitable
for conversionwith a JAMAICAN body
the MG, TA. This car featured a 1.3 liter, 5 0 BHP four cylinder
englne. I n April, 1 9 3 9 the TA was replaced by a new model with minor refinemerlts, the MG fB. The
total T A and T B production, before it was discontinued as a result of WWII, was only 3 4 0 0 cars.
--
Shortly after the war, the T B was revived in a new form as the MG TC which was soon followed by the
TD. Both were equipped with 5 7 . 5 BHP engines. In 1 9 5 4 the 63 BHP TF 1 5 0 0 was introduced but
was short-lived because i n 1 9 5 5 production was commenced on the MGA which offered a 78 BHP en ine.
The MGA series offered several interesting options
disc brakes (front), wire wheels and a twin over ead
cam engine in place of the standard pushrod engine.
--
R
I n 1 9 6 2 , the MGB arrived on the scene but as previously mentioned, its unibod constructipn precludes its use as a vehicle for the JAMAICA^. A l l of the cars listed above, except t l e MGB will accept
Lilr ..iAMkiCA:i body i n a s ~ ~ l uas
c l ~they all have frames separable jrorll tile bodym~l; .i,,:t h q ;.\I hall? 9a"
wheelbases.
Market response for the JAMAICAN has revealed, however, that 9 9 % of the bu ers using the body on
MGs were using a MGA. Therefore, the JAMAICAN is inner-paneled to f i t the M G series
~
exactly although
the body can be used with the MG TA, TB, TC, TDor TF.
TRIUMPH
In 1 9 5 2 when Standard took over the Triumph Company to form the standard-Triumph Motor Company,
the Standard Vanguard engine was modified to 2 liters developing 100 BHP and fitted to a Triumph
Mayflower chassis to create the T R 2 sports car. Since 1 9 5 2 the TR2 has evolved through the TR3 to
the T R 4 and currently the T R 4 A with independent rear suspension. A I ~these cars ha* been fitted with
front wheel disc brakes and all have an 88" wheelbase.
'The inner-paneling for the JAMAICAN-for-Triumph has been designed to f i t all TR1s with two basic
models --one for T R 3 and T R 2 and one for TR4, TR4A, TR4A-IRS, and TR 2 5 0 . Ttlerefore, when a
JAMAICAN-for-Triumph i s ordered the model must be stated.
3. PREPARING THE CHASSIS
The first step in the building of your new JAMAICAN is to prepare the chassis for the JAMAICAN body.
The following tasks to be completed are common for all vehicle types.
1. Remove the battery.
2.
Drain the gas tank.
3. Remove gas tank filler hose and cap assembly, and tape shut filler neck with masking tape.
4.
5.
6.
7.
Remove seats and a l l upholstery.
Remove windshield and wiper arms.
Remove doors.
Remove spare tire.
8. Remove hood-cover engine with tarpaulin or equivalent.
9. Remove deck lid.
1 0 . Discorlnect all wirinq to lights srld fue! t ~ v ' r .a d pr~tecbille!ytape thc :.di;.;.ends.
11. Remove headlights and parwturn lights.
1 2 . Remove license I ight-bracket.
13. Remove windshield wiper motor and mechanism.
1 4 . Remove bumpers.
1 5 . Remove fenders (most bolts are located inside wheel wells).
1 6 . Drain engine and radiator of water.
1 7 . Remove radiator.
1 8 . Remove instruments and panel controls and protectively tape the wire-ends.
For the next steps, turn to the section describing your particular chassis.
AUSTIN-HEALEY
1. Un-bolt relay, fuse block, volt regulator, etc., from firewall and place them down out of the way.
2. Remove gas tank.
3. Remove front bumper brackets and horns.
Cut off outer skin at fendu line.
Referring to Figure 2A* :
a. Remove rear cross braces (between fender inner panels).
b. Remove rear fender inner panels (down to chassis).
c. Remove cowl brace (stamped sheetmetal).
d. Remove lower door s i l l s and front hinge posts (see detail for cuttirlg side panels).
e. Cut 2" off top of firewall.
f. Remove body mount brackets and cross brace from front wheel wells.
g. Trim 4 " off of outside of wheel wells, parallel with center seams.
6. Remove mounting brackets from radiator and replace 2 " higher on radiator.
7. While holding radiator in place on chassis mark section of frame cross member that interferes with
lower hose outlet. Cut this section out o f cross member.
8. Bolt radiator i n its new position.
9. Trim off all protrusions on inside (cockpit side) of firewall above heater duct.
4.
5.
Un-bolt relay, fuse block, volt regulator, etc., from firewall and lace them down out of the way.
Remove heater assembly including defrosters. (The blower side oPthe heater box w i l l have to be
dropped 1 - 1 / 4 inches. This i s easily done by dis-assembling the box, cutting a wedge out of
the side panels, bending new tabs and re-assembl ing the box.)
Remove outer skin at fender line.
Remove cowl support bracket.
Referring to Figure 2Bk :
a. Cut front wheel well panels just ahead of radiator mounting flanges.
b. Un-bolt front bumper support brackets.
c. Remove nose section.
d. Remove door sills, and rocker panels.
e. Cut side panels (with hinge posts) straight dowri 2 " back from upper firewall (vertical surface
where relay, fuse block etc., were attached).
f. Remove rear fender inner panel cross brace.
g. Remove rear fender inner panels down to inner floor surfaces.
h. Cut upper firewall straight across from fender panel-to-fender-panel, and trim off all protrusions from inside of remaining panel.
i. Fabricate radiator mounting flange extensions so that radiator can be mounted down 2 " and
forward enough to clear lower hose.
*HEREINAFTER AN ASTERISK FOLLOWING A FIGURE NUMBER REFERS TO THE BLUEPRINTS.
1. Re~liovegas tank.
2.
Remove outer skin.
3. Remove a l l hardware from upper firewall.
4. Referring to Figures 2Ctand 2 D :
*
5.
a. Remove upper firewall above horizontal surface.
b. Remove entire rear fender inner panels and trunk floor.
c. Remove rocker panels and side panels (with door hinge posts).
d. Removefront fender inner panels 2 " ahead of radiator mounts.
Move mounting brackets on radiator up 2 " and re-mount.
The followirig again refers to a l l veliicles, We recomrllend a t this point, t l ~ a tlle
t
chassis be cleaned
o f f (steam, gunk etc.) arid painted will1 a rust preventive pairit.
I f you are planning an engine "swap" the installation of the new engine should be done before mounting the body. Seesection 9 for V-8 engine installation details.
4.
MOUNTING THE JAMAICAN BODY
We recommend that, prior to mounting the JAMAICAN body on the chassis, a few preparatory steps be
completed on the body while access to a l l areas is s t i l l possible. First, with the body upside down, trim the
wheel opening flanges back to about 3/4" and sand smooth. Trirn each rocker panel to an equal dimension
from the door s i l l and sand smooth. Trim the tail section return as per Figure 4, and sand smooth. Then,
with the body right side up again, cut the windshield and rear window openings to 3/4" from s i l l , cut out the
door opening, leaving a 1/2" flange above the fender line (window opening, Figure 3E*) and at least 4 "
flange below the fender I ine (Figure 3 P ) . The lower flange w i l l be trirnmedlater after the body is mounted to
the chassis.
We suggest that Uie t a i l section be wired prior to mounting the body while the inside of that area is
readily accessible. See Section 6 for wiring details. Be sure that the inner panels are correctly seated on
the mounting surfaces of Uie chassis. Do not fasten down the body at this time, but proceed to the next step
mounting the doors.
----
e c t i o n Inverted
c u t Out and
Remove
Y
y
f-
---
'IGURE 4
%
'
MOLlNTlNG THE DOORS
Before the doors can be mounted, the following steps must be taken:
1. Trim the door edges back to the scribe l i n e on the outside skin.
2. Cut the window slot in the top surface as per Figure 5.
3. Attach the door window trim as illustrated i n Figure 3H*.
With these steps completed the doors may now be located i n the body and temporaril y held i n place with masking
tape. Particular attention should be given to the f i t down the rear edge of the door and the area under the windshield post. Any mis-alignment along the bottom edge of the door may be corrected when bolting the bod rocker
panel (area beneath the door) to the chassis. Now locate the hinges as i n Fibure 3Bk and mark the bolt K o ~ e
locations on both the body and the doors. Remove the doors and d r i l l out the holes, using a d r i l l b i t from 1/8"
to 1/4" larger than the mounting bolts. The extra large holes w i l l allow adjustment for a perfect fit. I t i s
advisable to use a backing plate inside the doors for added strength when bolting the hinges to the doors. A
plate 1/8" thick and the same shape as the surface of the hinge that bolts to the outside surface of the door
should suffice. We have found that a nut-plate for the body-half of the hinges makes installation and adjustment
much easier. These plates again may be fabricated of 1/8" steel plate (although 3/16" allows for more threads)
approximately the shape of the hinge surface. D r i l l the bolt holes (undersize) and thread for the mounting bolts.
If access to the back of the hinge-mounting surface i n the body is not available, cut a 3 " to 4" hole between the
upper and lower hinges so that the nut plates may be inserted and secured. The doors may now be installed, with
'1," ' - ; * , y ( : : ; ! o ~ ~ < ~ ? t . , ~ . l ~l:> : . l \ c c l
I"
ct79y
The door latch r n e c l ~ a n i s ~ rillustrated
~,
ill F i g u r e 3 P , should be mounted riext. Since such a w i d e
variety of latclics are available, each w itli i t s own s p e c i f i c i n s t a l l a t i o n rnetliods, all attetr~ptw i l l not be ~r~acle
here to describe the latcli instal la ti or^.
After tlie door i r ~ s t a l l a t i o nhas been completed, the r n a i ~body
~ section may be bolted to the chassis
(remember to a l i g n t l ~ erocker panels wit11 the doors when attaching these sections).
MOUNTING THE HOOD
Before placing the hood i n p o s i t i o n on the chassis, t r i m the rear edge (at c o w l and doors) of the hood
back t o the scribe l i n e and trim the wheel opening flanges as per the rear wheel openings. Place the hood
on the cowl and block the front up until body crease l i n e s up along the rear fenders, doors and front fenders.
Mark the rocker panel overlap and trim for minimurn gap. Wit11 the hood located i n correct p o s i t i o n make
cardboard templates of tlie hinge brackets. These brackets should be bolted or welded to the main chassis
rails. See F i g u r e 6 for a typical i r ~ s t a l l a t i o n . B e sure to use a t l e a s t 1-1/2" steel angle or 3 / 1 6 ' ' steel
strap for bracket material for strength.
S H I N WITH W A S H E R S T O R A I S E /,/
OR LOWER ( p a r t " 0 " )
A U X I L I A R Y HOLES D R I L L E D FOR
fORWARD AND AFT ADJUSTflENT
CONSTRUCTION AND ASSEMBLY
FRONT HOOD H I N G E
F O R JAMAICAN
5.
INSTALLING THE WINDSHIELD, REAR WINDOW AND DOOR WINDOWS
'The JAMAICAN body i s designed s b e c i f i c a ~to~ use
~ the Chevrolet Stingray windshield and surrounding chrome trim. The windshield i s supplied as part of the D E L U X E kit. The chrome trim i s available from
your local Chevrolet dealer (see P A R T S L l S T for appropriate part numbers) i f you wish to use i t on your
JAMAICAN.
The windshield i s installed using the installation k i t and silicone rubber sealant listed in Section 1,
under Construction Materials. If chrome trim i s to be used, twenty trim-retaining clips should be secured in
place around Uie edge ot Uie window opening before tlie glass is installed. Small, flat-head wood screws
w i l l suffice to hold the retainers securely. The material in the installation k i t
"butyl tape" (which has
the appearance of a 3 / 8 " diameter rope formed of a tar-like substance)
i s now pressed into place along
the l i p of the windshield opening. Then, the glass i s l a i d i n place in the opening over the tape and pressure
i s applied to compress the tape to about 5 0 % of its original thickness. Now, the silicone rubber sealant
even on the retaining c l i p s
and the chrome trim i s immediis squeezed in the gap around the glass
qtely installed by p r ~ s s i n ?i t into tho c l i p s and sealant. Remove the excess sealant as rn*?n-* y " s * l e
before i t commences to set. DO NOT DISTURB THE G L A S S FOR A T L E A S T EIGHT HOURS AFTER
INSTALLATION.
--
---
--
---
The rear window opening i s designed expressly to accept the Porsclie 9 1 2 rear window. The DELUXE
K I T i n c l x e m a r window glass. The chrome trim i s available from your local VW-Porsche dealer ( see
PARTS L l S T for numbers). The rear window i s installed in the same manner as the windshield. However, i f
chrome trim is to be used, the glass should be placed l i g h t l y on the installation material while the sealant i s
squeezed in the gap and on top edge of the glass. The clirome trim should be placed immediately around the
glass and the entire assembly pressed into the installation material. Again, remove the excess sealant.
The JAMAICAN door window openings are designed to accept VW Karmann Ghia ( 1 9 6 0 - 1 9 6 3 ) door
windows. The door inner panels are designed to accomodate the above mentiorled windows and to support the
s l i g h t l y modified VW Karmann Ghia (see P A R T S L l S T for part numbers)
for
roll-up mechanism
raising and lowering the side windows with a standard crank.
---
---
Figure 7 shows the guide-track and roll-up mechanism (for the l e f t door). The bottom 1" of the guidetrack must be cut off to f i t i n the JAMAICAN door and the two positioning p i l l a r s should be re-ta ped to 5 / 1 6 1 8 to accept the 5 / 1 6 - 1 8 x 2 - 1 / 2 " f l a t head machine screws required to fasten the track to e!t
door inner
panel. D r i l l and counter sink the holes i n the door inner panel as illustrated i n Figure 3 A * for the guide-track
screws. lnsert the 5/16" f l a t head screws in the holes and run lock washers and nuts up the screws on the
inside of the panel until they are near the panel. lnsert the guide-track through tlie long slot i n the panel and
screw the flathead screws about 1 / 4 " i n the positioning pillars.
lnsert the mechanism
Re-tap the four tapped holes i n the roll-up meclianism,(Figure 7 ) to 1 / 4 - 2 0 .
through the large slot in the inner panel, insert the roller on the end of the arm into the cross-track on the
guide track and bolt to the d e p r e s s i o s i n the inner panel with 1 / 4 - 2 0 x 3 / 4 I f hex head bolts.
Next, f i t the rubber grommet i n the glass holder, f i t the two bolts (be sure to use the original VW
bolts) i n the inner holes. lnsert the assembly through the s l o t i n the top of the door and secure to the guidet r a c k The closed window may now be adjusted to f i t the window opening by closing the door, cranking up
the window and adjusting the guide-track ositioning screws on the inner panel. When i n tlie correct position
tighten the nuts on these screws against tRe inner panel and adjust the l i m i t adjustment (see Figure 7 ) so that
the glass cannot be raised above this position.
6. WIRING AND INSTRUMENTS
This section of the instructions provides tlie ground-rules for completing the basic wiring of your
JAMAICAN. In many instances, especially if tlie chassis was not acquired as a wrecked vehicle, the
wiring harness should be intact arid usable; some lengthening or shortening of particular wires may be necessary but, in general, the Austin Healey, MG or TR factory-installed wiring harnesses are adequate for tlie
JAMAICAN.
In the cases where the original harness has been partially or totally destroyed or a radically different
(from the original vehicle) electrical instrument/component layout (e.g., as a result of an "engine-swap")
is desired, the following wiring guide sliould be helpful.
A basic wiring harness sliould provide for:
1. Starting
2. Ignition
3. Basic Instrumentation
-- te~nperature, o i l pressure (guayes or warning liglits), fuel level, and
battery/generator corid i t ion.
4. Interior and exterior lighting
5. Battery-charging and ground circuits
6. Accessory power and control
windshield wipers, horn, heater fan, etc.
--
A t this stage in construction, most items to be wired have been installed; e.g., the starter, the
starter solenoid, ignition coil, o i l pressure arid water temperature senders, battery charging indicator
(voltage regulator) and fuel level sender unit are a l l available for wiring. Lights, however, are yet to be
installed.
T A I L LIGHTS
AS was mentioned i n Section 4 , tlie rear body section should be wired before mounting with plugs
for ease o f installation. The two common wiring techniques covering a l l chassis applications are illustrated in Figures 8a,b,c.
If your chassis had a single tail l i g h t bulb per side, an eight-contact Lucas
relay may be found under the hoodand F i g u r e 8 b should be used. For a dual tail l i g h t bulb installation
(no relay), use Figure 8c. We recommend Lhat the original turn signal/brake light configuration be retained
to simplify the wiring task. In either case, locate and secure the light sockets to the body and wire as per
the applicable diagram. D r i l l holes through the inner panels and connect the male end of 4-prong plug or
plugs near the center of the rear body panel (on the inside). Be careful to note the function of eachwire
being attached to a plug-pin inasmuch as these functions must carry through to tlie plugs wired on the
chassis.
HEADLIGHTS AND PARKING LIGHTS
-
Headlight brackets should be fabricated as shown i n Figure 3W and secured to the headlight bucket
backing plate. Cut a 7 - 1 / 8 " diameter hole in the center of the headlight-tunnel and bolt the assembly i n
place. P a r u t u r n lights can be installed on sheet-metal brackets located i n the g r i l l e opening. Remember,
when mounting the lights - - o r for Lhat matter, any electrical component
i n fiberglass, unlike steel bodies,
that a S E P A R A T E GROUND WIRE M U S T B E INCORPORATED IN T H E WIRING HARNESS i n order to complete a l l circuits back to the battery "ground" terminal.
---
INSTRUMENT PANEL WIRING
Your JAMAICAN body is delivered to you w i t h a fiberglass dashboard already laminated i n place.
The dash i s designed to u t i l i z e a centralized instrument/control cluster
this cluster i s the hub of the
wiring harness and should be carefully planned. The basic instrument/control requirements a r x a t i s f i e d
by the following indicators, sw~tches, etc.:
--
Controls
1.
2.
3.
4.
--
Key-operated ignition switch
Headlight/parking light switch
Headlight dimmer switch
Accessory control switches, as required.
Indicators
1.
2.
3.
4.
5.
6.
--
Fuel level gauge
Water temperature gauge or l i g h t
Oil pressure gauge or l i g l i t
Ammeter or charge/discharye warning light
Headlight high-beam "on" indicating light
Speedometer (non-electrical).
CHASSIS WIRING
The wiring harness i s divided in two major pieces
-- hub-to-front
and hub-to-rear.
The hub-to-
front wires are routed from the hub (instrumenVcontrol cluster) torward
the Firewall arid then t
h
grornmetted hole in the firewall above and to the right of the steering column. Engine instrumentation,
to
i
ignition and starter solenoid leads end at a terminal block mounted centrally at the top of the engine side
of the firewall. Lighting leads continue forward along the frame rail and terminate in female connectors
which mate with the male connector serving to terminate the in-the-hood wiring. Connection is made at
a point on the frame ahead of the front wheel center1 ine.
NOTE: Provide sufficient wire for the male corinector to reach the female connector even with the hood
fully open.
The hub-to rear harness i s routed from the hub forward to the firewall, along the firewall to the
righthand wheel-well, down the firewall to the floor, around the well, under the door-jamb to the rear
wheel-well, over the well to the rear of the body.
T H t iiib-TC-;;.EAR
tiARNESS CONTAINS:
1. Hub to brake lights
--
one #10 wire i n the harness to the RH light, then across Ule rear to the
LH light. (DON'T FORGET
.. - TO GROUND THE LIGHTS TO THE CHASSIS!)
2. Hub to tail lights -- one #10 wire routed the same as the brake lights.
3. Fuel gauge to fuel-level sender -- one #16 wire to the tank sender terminal.
4. If the battery is rear-mounted, the ammeter-to-battery connection is made in the following
manner. Connect the battery "hot-side" to the starter solenoid via 12-volt battery cable
run adjacent to a fore-and-aft frame member. Connect the ammeter to the same solenoid
terminal via #10 wire run i n the hub-to-front harness.
THE HUB-TO-FRONT HARNESS CONTAINS:
1. The hub to brake light switch and return -- two 810 wires to the firewall terminal strip (from
the terminal, two #10 wires go to the brake light switch mounted on the brake master cylinder
2.
3.
4.
5.
or in the forward brake lines depending on the vehicle.] These wires carry battery "hot-side"
to the pressure switch and back to the hub for distribution to the rear.
Temperature and pressure indicators t o appropriate engine mounted senders
two #16 wires
from the terminal block two #16 wires to the senders.
to the terminal block
Ammeter to voltage regulator
one #10 wire to the terminal block
one #10 wire from the
block to the "armature" terminal on the regulator.
Headlight switch to parking lights
one #10 wire from the hub to the six-pin female connector.
Headlight switch/dimmer switch (dash mounted) to low beams
one #10 wire routed as parking
light wire.
--
--
--
--
--
--
6. Headlight switch/dimmer switch (dash mounted) to high beams --same as low beam.
7. lgnition switch to starter solenoid
---
--
one #10 wire to the terminal block
one #10 wire from
the block down the firewall to the solenoid.
8. lgnition switch to starter solenoid
one #10 wire to the terminal block
one #16 wire from
the block to the coil l'BAT.ll,"SW.",
etc. terminal.
9. If the battery is front-mounted, i.e., under the hood, an ammeter-to-battery connection i s required in the hub-to-front harness. Use #10 wire to the terminal block and #lo wire from the
battery terminal as hot and1'-" terminal
block to the battery "hot-side" (U. S. cars use the
for ground, British cars with LUCAS ignition and electrical system use the reverse, i.e.,
"-" is hot.)
--
"+"
'The items of inslrumentation mentioned above may be ordered from your local Stewart-Warner dealer
or directly from Fiberfab. See the parts l i s t for the recommended set Stewart-Warner gauges and senders.
Some " u ~ ~ l ~ a r ~ i e s sconr~ections
ed"
are required i n fie engine compartment. They iricludc:
1. Ignition coil "DIST", etc. terminal to the distributor
2 . Generator/alternator Field to the voltage regulator
--
use # l b wire.
-- use # 1 6 wire.
--
3. Generator/alternator armature to the voltage regulator
use # 1 0 wire.
4. Battery "hot-side" to the starter solenoid -- use 1 2 - v o l t battery-cable.
5. Battery "ground-side" to grou~id(some point on tile frame close to the battery) -- use 1 2 - v o l t
battery-cable.
The preceding material should serve as a guide to the basic w i r i r ~ gof your JAMAICAN.
Additional items such as horns, direction indicators, tachometers, etc., can be added at your discretion.
In general, all additional wiring can be simply added into the hub-tc-front or hub-to-rear harness without incurring any special routing problems.
ROLL-UP WINDOW MECHANISM PARTS
lde~ltificatiollby Voll(swayeti Part Nunibers
REGULATOR
L E F T DOOR
1 4 1 8 3 7 501B
RIGHT DOOR
1 4 1 837 502B
TRACK ASSEMBLY
1 4 1 8 3 7 5516
1 4 1 837 552B
GLASS HOLDER
1 4 1 837 5 T l k
14;
WINDOW GLASS GRCMR;lET
1 4 1 837 5 6 5 ~
1 4 1 837 5 6 5 ~
FIGURE 7
Tap to 5/16-18
237 571,?1
7. UPHOLSTERY -- INTERIOR FINISHING
The upholstering of your JAMAICAN is purely a matter of personal taste. You can be as simple or
as elaborate as you desire -- austere for the road machine, buff or "posh" for the grarid touring enthusiast.
A t the factory, we use, of course, the JAMAICAN upholstery k i t (available at extra cost). The
standard upholstery k i t corrsists, i n part, of automotive-grade carpet cut to f i t tlte floor, firewall and headliner surfaces and bound with plastic, sewn binding to prevent ravelling. The carpeting is affixed with 3 M
(Copyright, Minnesota Mining and Mar~ufacturing)Trim Adhesive dispensed from a spray can.
Wood blocks should also be glued into the windshield pillars to provide attachment points for the
upholstered pillar panels -- again easily constructed of vinyl over cardboard and foam rubber.
I f you have access to a co~nmercialsewirig machine you can make your own carpeting, rugs, etc.
Use heavy paper to make a pattern of Uie interior of the car. Transfer this pattern to the carpet (making
sure i t is not upsidedown) and cut. Sew on the binding. Spray the surfaces to be covered with trim adhesive. Install the upholstery. Use the same "paper pattern" technique to develop the door panels, windshield pillar panel, etc. , shapes.
In the area behind the seats (under the rear window) plywood paneling can be inserted between the
rear wheel-wells and over the gas tank and spare tire compartment. Cut a pattern from a piece of corrugated
cardboard and transfer this to 1/4" plywood
use marine plywood and varnish well before installing.
The plywood interior surface can be painted to match the upholstery or covered w i t h carpet l i k e the
floor and headliner. Chrome skid strips can be tacked over the carpet, running fore and aft at a 4 " to 5 "
spacing
these strips allow luggage to be easily placed behind the seats without scuffing the carpet.
--
--
Upholstered door panels, available as part of the standard upholstery k i t are attached to the door
inner panels with plated phillips head sheet metal screws w i t h finishing washers.
As a finishing touch, a courtesy light can be installed overhead on the vehicle centerline just forward of the rear window. Wiring is routed up a windshield post and under the headlirier material. The
operating switches are mounted facing up through the door jamb at the very front of the jamb, out of the
way of entering and exiting feet.
The stock Austin Heale , M W , or Triumph heating system can be utilized w i t h the JAMAICAN
body. New ducts must be cut tlrough the top of the dash to allow defroster air to reach the windshield.
* See chassis preparation for minor modification to MGA heater box.
8. EXTERIOR F I N I S H
Tlle ~lrostirnporta~~t
item i n t l ~ earca of exterior finis11 i s , of course, tlre 11ai11ti11cl.Fil,crglass is
111ost compatible with acrylic lacquers. Lacqucrs, also, are the easicst and 111osttro~rble-frce ill t l ~ e i r
app[ ication. They call eve11 be appl icd ill a s l iglltl y dusty crrvironlnent
the dtrst a ~ r dspraying imperfections can be rubbed-out st~bseqirer~tly.Just f o l l o w tlte paint i r ~ s t r ~ t c t i o ratid
~ s don't try sprayirly on
cold and/or damp days.
--
About body surface preparation -- most fiberglass bodies have s l i g l i t inlperfections such as p i n
lloles or mold~narks. Often they w i l l pick up a fcw scratclles during shipment. I t is virtually i m p o s s ~ b l e
to avoid this. Body putty and s a ~ l dpaper should take care of any body f i n i s h problems you might have.
We are proud of the finished sllrlace of our bodies. We m e special care and materials around the
edges of the body surface to prevent cllills. One of our own A Z T E C S , w i t h over 5 0 , 0 0 0 miles on it,
does not have one body crack irl it. I t s t i l l has i t s original paint job, too!
Your JAMAICAN body w i l l have a color when you receive it. I n most instances, t h i s color w i l l
riot the finished color. T h i s i s a special gelcoat your body has been given to achieve
be black. This is a better surface.
Before you paint your J A M A I C A N the entire body should be l i q l l t l y sanded w i t h k 4 0 0 sandpaper.
Rerrrember to go
liglltly! Then the body should be washed off and wiped witlr Prepsol or some other p a i ~ l preparation
t
liquid
to eli~nitlateany o i l or dirt. The body i s now ready for primer and paint.
Tile body i s sanded in order to "scuff up" the surface wllich i s too s X X G hold paint.
Other Items of Exterior F i n i s h Are:
--
The A u s t i n Healey, M G and TR witldshield wiper actuator systems are almost
WINDSHIELD WIPERS
<dent~cal,one to another. They consist of a 1 2 - v o l t motor driving a crank which p u l l s and puslles a cable
inside a tube. The wiper pivots are mounted on the tube and engage the back and forth rnotion of the cable.
Installation in the J A M A I C A N i s simply a matter of nlounting tlre 'pivots i n two holes d r i l l e d through the
cowl as shown i n Figure 3F*. Ttre niotor i s brought to a convenient mounting location by gently bending
the cable-bearing tube u n t i l the motor contacts the desired mounting surface.
--
The only place the J A M A I C A N may require weatherstripping is around the hood
WEATHERSTRIPPING
and doors. We suggest, for the hood, using a t h i n strip (3/4"wide) of adhesive-backed foam rubber.
Typical stripping material is found, for example, i n the Sears catalog bearing # 2 8 A 7 2 2 6 . Apply the
stripping after painting. The door weather s t r i p (Figure 3Gf')i s a combination windlace and weatherstrip,
a v a i l a b l e r a standard item w i t h the ~ ~ p h o l s t e rkit,
y and i s installed by simply slipping over the prepared
fiberglass flanges.
9 . V-8 POWER OPTION
Soon after World War II, [lie sports car busitless besari to flourisli w i t h Llie iritrodoctiori of Ule MGTC -- and soon after i t s iritroductiori certain owriers irievitably wanted more "go". Some enthusiasts welit
tile supercliarger/super-t~r~iirig route largely will1 disastrous results -- tlie ~ i o t a b l eexception was the magnificent (arid very experisive) " o l d 83", arid M G - T C f i t t e d w i t h all I N T E R M E C C A N I C A blower, iritercooler
and special body.
Otlier builders resorted to tlie " e ~ i g i ~ iswap".
e
The M G e r ~ g i n ewas replaced by [lie ver~erable
if suitable c o ~ ~ s t r a i ~OIIi t se ~ i g i ~s i~z e a ~ i dpower were applied -,Cord V - 8 / 6 0 Substituting engirles
proved far more satisfactory fliari to "liop-UO" the stock engine.
--
Today tlie V - 3 / 6 0 IGISlorlg been superceded by tlie Clievrolet 233 ctl.
by tile Ford 2 8 9 cu. in. V - 8 "Fairlane e~igirie".
Iri.
V - 8 arid more recent1 y
Any of the veliicles suitable for use w i t l i a J A M A I C A N body are also suitable for either of these
V-gls. Tlie Austin Healey 3 0 0 0 series cllassis i s probably tlie best to use i f etigirie outputs exceedirig
7 5 DUD a- beirlg c n n q i t l ~ r e d . We ~*/ouldrecomrriend, in an;! ca:c, that tlie liorsepower r ~ o exceed
t
250
~ H unless
P
the entire frame, drive-line and suspension are reworked to safely contain the tiiylier power.
~ i engine swap is, obviously, before
The best time durirlg the J A M A I C A N coristruction to p e r f o r ~the
tile body i s mounted. I n tlle course of preparirig the cliassis, rernove the original engine, tlie engine mounts
atid [lie transmission and i l s mounts. (Note: Tlie stock transmission car1 be retained for low power
under
150 B H P
installations a ~ i dif a suitable engine-to-gearbox adapter is available).
--
--
Tlie "riew" V - 8 arid gearbox (we used a Warrier T - 1 0 box and a Ford 289 for our Healey-JAMAICANFord, and a Buick Aluniinum V - 8 for our MGA-JAMAICAN-Buick*) are lowered into tlie engine compartment
and blocked i n position. New engine and gearbox mounts are now fabricated, f i t t e d to Uie eriyine-gearbox
inplace, and welded to tlie frame.
Once tlie engine and gearbox are permanently installed, the drive-sliaft car1 be shortened by cutting
and welding (make certain i t i s straight after welding) arid Llie HURST-shifter can be iristalled.
A high capacity radiator, sucli as tlie Harrison aluminurri radiator for Corvette, sliould be installed.
A surge tank should be mounted w i t h tlie f i l l e r opening above the level of the cylinder heads.
No significant modification i n w i r i ~ i gsliould be required -- Lhe ignition systern remairis 1 2 - v o l t .
Only the o i l pressure and water ternperati~resending units may be different.
--
Several notes i n closing
a good reference for H U R S T parts, special engine/gear box mounts,
Instruments, etc., i s the "Honest Charley" catalog available from:
HONESTCHARLEYSPEEDSHOP
Honest Street a t North H i w a y II
Chattanooga, Tennessee 3 7 4 2 1
-
When acquiring a wrecked veliicle for a JAMAICAN arid ari engirie swap i s contemplated avoid
choose tlie d i s c wlieels for s t r e n g t h n d durability.
cars w i t h wire wlieels
--
P L E A S E F E E L F R E E TO C O N S U L T U S ! Wlien you are buildirig your J A M A I C A N , i f you encounter some problems outside the scope of these illstructions or are having trouble obtaining any of the
materials you need, do not hesitate to contact us. We w i l l be pleased to a s s i s t you i n any way we can.
" For details concerning tlie V - 8
iristatlatiori, coriiact otrr factory.
1 0 . THE JAMAICAN-VOLI(SWAGEN
T l ~ eJAMAICAN-VOLKSWAGEN c o ~ ~ v c r s i io~~i si t r t ~ c l i oarc
~ i s set apart fro111Ll~cI ) a l a ~ ~ cofe 1l1e ~ i ~ a l c r i a l
ill tllis 111a11t1al
because of the largc I I U I I I ~ J C ~of IIII~CI~IC p r o c c d ~ ~ r ci s~ ~ v o l v cilld COIIIJ)ICL~II~
lliis rear-cngi~icd
i I~owevcr,
variation. Sections 1, 2 a~icl4 t l i r o ~ ~ g3l i arc a p p l i c a l ~ l eto your VW-based project. S e c t i o ~3,
is supercedetl by t l ~ ef o l l o w i ~ ~~g~ ~ a t c r i a l .
REMOVING THE VOLI<SWAGEN BODY
Before you start to cl~ll)olttllc body, rerliove the front and rear seats, discorir~ectand relllove tlie battery
Next, relllove t l ~ cl e f t front tire/wl~eel ill order to urlbolt tlie steering shaft by rerni,vi~iy
two bolts fro111tile steering shaft u ~ ~ i v c r s joint.
al
Now d i s c o ~ ~ ~the
~ c cIiorn
t wirc.
slid drain tlie gas tank.
Now discon~iectthe I I I ~ I ~ Lc lI~~o~k ecable or tlie wire from tlie electrically operated clioke.
wires (to tlie coil a ~ voltaye
~ d
regt~lator)and ~ L i e l L l u i u ,caLI? fro;,, ~ I I C
~~:;i~ic.
Discon~iecttlic
Remove tlie choke froni t l ~ edasliboarrl (110 dasliboard c o ~ i t r o lexists for tlie electrically/tl~er~nostatically
operated c l ~ o k e )a ~ i dpull tlie cable tlirougli to remove it. Discon~iectt l ~ egas l i ~ ~ etos the gas tank and remove
tile tank by llnbolting (see Figure 9 ) a ~ l~i f d
t i ~ i gi t up and out. Don't forget tlie reserve fuel switch-over valve
in t l ~ ecockpit.
You are now ready to unbolt t l ~ ebody. F i r s t , relnove tlie bolts located alorig the outside edges of the
llliderside of the floorpall (see Figure 9 ) . Next, relnove the several bolts r e l ~ ~ a i n i at
~ i gtlie front underside of
tile floorpan
just inside tlie front wheel-wells.
--
i
rear seat was taken out. F i n a l l y , remove the rear tires/wlieels
Remove tlie four bolts exposed w l ~ e l the
arid unbolt the body bolts ill tlie wlieel-wells. SAVE THESE B O L T S !
The body s l ~ o u l dnow be free to be lifted off via block and tackle, cl~ain-hoist, or yourself and "several
strong and willing helpers." CAUTION : Tlie Volkswager~llody i s extreniely Iieavy! I t is because of this
weight loss, incidently, that you rnay expect better-tliarl-Volkswagen pertortr~arice111 your completed
JAMAICAN-VW.
Care should be exercised when l i f t i n g off tlie Volkswagen body in order to preserve the body-to-floorpan
rubber seal. I t can be used to "weatherstrip" your new JAMAICAN body.
I t is advisable to save a l l tlie undamaged parts such as tlie steering colutnn and wlieel, gas tank,
struments, etc., inasmuch as these items can be used to complete your JAMAICAN.
in-
INSTALLING THE F R A M E R A I L S
The frame rails are installed next. Remove the dust covers ( 4 bolts each) from over tlie elids of the
rear torsion bars (covers on early chassis f i t around the end of Llie torsi011 bar leavirig i t exposed, while
covers on late chassis completely cover tlie end of the bar).
Modify the dust cover as shown i n Figure 10 and replace t h e n on the floorpan with the upper two bolts
(don't forget to put the rubber "dougllnuts" back under the covers.) Bolt the end-plate of tlie frame r a i l s to
the floorpan over the dust covers using the bottom two dust cover retaining,bolts
leave the bolts loose.
L i f t the front end of tlie frame r a i l and secure i t under tlie lower, front tors1011bar housing (tube) using the
U-bolts provided with the frame rails. Position tlie U-bolts about 13 inches either side of tlie floorpan
centerline
tigliteri a l l bolts. Secure tlie edge of the floorpan to tlie r a i l s by d r i l l i ~ i gtlirough tlie 'pan
Into the 'rails and f a s t e r ~ i ~with
ig
large sheet-metal screws.
--
--
FIGURE 1 0
REPOSITIONING THE COCKPIT CONTROLS
With the floorpan supported by the frame rails, the central tunnel of the floorpan can be cut and "rearfull
sections are
three
ranged" in order to relocate the pedals and gearshift. Referring to Figure 9
cut from the tunnel and replaced as shown. The cutting can be accomplished using a sabre-saw or an oxycuts
acetylene cutter. Cuts should be made along the side of tlie tunnel as close to the floor as possible
up the sides should be perpendicular to the floor. Care should be taken to cut only the tunnel, not the tubes
and cables running within the tunnel.
--
--
Figure 11shows the reconfigured VW 'pan ready for the JAMAICAN body. For the pedals to operate
i n their "new" position the clutch and accelerator cables must be shortened by cutting-off 1 4 1/2 inches and
reswaging the end fittings to the cut ends. The tubing surrounding the accelerator cable i s puslled back inside
the tunnel and .cut-off flush a t the point it exists the rear of the tunnel. The pedal pivot support tab is re-bolted
to the pan through a new hole drilled i n the 'pan after the pivot is securely i n its new position.
Repositioning the steering column and wheel is accomplished by lowering (reducing the angle between the
'pan and the column) and lengthening the steering column/shaft. The required lowering i s quite simple. The
VW steering box i s only clamped on the upper front torsion bar housing. I t can be rotated on the housing just
by loosening the clamps. With the clamps loosened, the steering box should be rotated such that the steering
linkage just clears the "hump" i n the center of the floorpan when the wheels are turned from lock-to-lock.
(Lowering the steering box alters the toe-in adjustment of the steering geometry. Proper toe-in i s reestablished by adjusting the tie-rods until the fronts of the front tires are about 1/8" closer together than the backs
refer to Figure 12. Make sure the adjustment i s divided equally between the tie-rods).
--
FIGURE 1 2
A simple metllod of lengtlienirig the stecring shaft the required 1 4 inches is to insert the extension,
sliown i n Figure 13, between the steeril~gbox and tlie steering shaFt. Tlie order of assernbly o f stecring
components i n a stock VW is: steering box, flexible rubber disc, "TI'-flange, stecring shaft. Tlie revised
order of assembly For the JAMAICAN/VW is: steering box, flexible rubber disc, 14'' extension, Flexible
rubber disc, "TIL-flange, steering shaft.
.
+I - 3'
FIGURE 13
MOUNTING THE REAR HANGERS
The final step i n preparing tlie floorpan i s to mount the rear hangers For the t a i l section of the GT-12
body. Figure 1 4 shows both hangers i n place on the mounts formerly used to secure the Volkswagen body.
When the Fiberglass tail section i s installed, shims (washers) may have to be placed under the front, rear
or both hanger-mounting feet (see Figure 1 4 ) to precisely align the t a i l section with the main body section.
I
FIGURE 1 4