jamaican - FIBERFAB.US

THE
JAMAICAN
APPLICATION:
Body Assembly manual
V-8
VW
X N G
548 Baldwin Street
Bridgeville, PA 15017
Phone 4 1 2-221 4200
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COPYRIOHT
"
1876
Revised:
INTRODUCTION TO FIBERFAB'S JAMAICAN V8 a n d V W BODY KITS:
E a r l y i n 1968, t h e JAMAICAN body s t y l e was i n t r o d u c e d a s a c o m p l e t e l y
new m o d e l t o s u p p l e m e n t t h e famous V a l k y r i e a n d Avenger l i n e .
The o r i g i n a l JAMAICAN was d e s i g n e d a s a d i r e c t r e p l a c e m e n t body f o r
Austin-Healey, Triumph
s e v e r a l 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 , 6.9.
and MGA.
These r e p l a c e m e n t b o d i e s a r e s t i l l c u r r e n t l y i n p r o d u c t i o n .
F o l l o w i n g t h e JAMAICAN'S i n t r o d u c t i o n , F i b e r f a b ' s e n g i n e e r i n g s t a f f was
d e l u g e d w i t h q u e s t i o n s c o n c e r n i n g t h e u s e o f V8 e n g i n e s i n t h e JAMAICAN
body s t y l e .
To answer t h e s e q u e s t i o n s , s e v e r a l i n s t a l l a t i o n s wore dea n d t e s t e d , e.g. t h e J A M A I C A N / M G A / B U ~ C ~ V8 u n i t r o a d t e s t e d by
TRACK magazine, March 1969.
Based on t h e i n t e r e s t shown i n a n d p e r f o r m a n c e o f t h e h y b r i d LIB'S,
F i b e r f a b l s e n g i n e e r s d e c i d e d t o b u i l d a " p u r e b r e d " JAMAICAN V8.
A t
t h e o u t s e t , t h e p r o j e c t seemed s i m p l e
j u s t b u i l d a frame t o accept
a V8 e n g i n e and t h a t f i t s u n d e r a JAMAICAN body.
However, t h e JAMAICAN
body was d e s i g n e d f o r a r e l a t i v e l y s h o r t - w h e e l b a s e , n a r r o w - t r a c k c h a s s i s .
A no compromise V8 c h a s s i s w o u l d be t o o l o n g and t o o w i d e f o r t h e exi s t i n g body
t h u s s t a r t e d a s i x month d e v e l o p m e n t o f a b r a n d new, w i d e r ,
t o u g h e r - l o o k i n g JAMAICAN V8 body a n d h i g h p e r f o r m a n c e c h a s s i s t o match.
--
-
S h o r t l y a f t e r t h e i n t r o d u c t i o n o f t h e JAMAICAN V8 k i t , r e q u e s t s f o r JAMAICAN a d a p t a t i o n t o VW c h a s s i s s t a r t e d coming i n .
Seems a s t h o u g h p e o p l e
b a c k t o t h e d r a w i n g board.
a r e n e v e r s a t i s f i e d , so
--
An i n n e r - l i n e r was d e v e l o p e d t o u s e i n t h e JAMAICAN V8 body, so t h a t i t
c o u l d be u t i l i z e d on t h e VW "Bug" c h a s s i s w i t h o n l y m i n o r m o d i f i c a t i o n s .
S i n c e t h e wheelbase o f t h e JAMAICAN V8 and VW c h a s s i s a r e e q u a l , t h e
a d a p t a t i o n was i d e a l .
C u r r e n t p r o d u c t i o n o f t h e JAMAICAN s e r i e s now i n c l u d e s t h e JAMAICAN V8
body and f r a m e k i t ; a n i d e n t i c a l JAMAICAN \hI body k i t s ; s i m i l a r body
s t y l e s f o r t h e TR3, TR4, TR250, A u s t i n - H e a l e y 3000 and MGA c h a s s i s .
A NOTE OF INTEREST:
A Japanese i m p o r t a p p e a r e d o n t h e A m e r i c a n m a r k e t i n
1970.
An i m m e d i a t e h i t w i t h t h e A m e r i c a n p e o p l e , t h e i m p o r t b o r e a r e m a r k a b l e r e s e m b l a n c e t o o u r JAMAICAN s e r i e s .
Not s u r p r i s i n g though, s i n c e
i t h a s been r e p o r t e d t h a t a F i b e r f a b JAMAICAN V8 was i n t h e p o s s e s s i o n o f
t h e A m e r i c a n i m p o r t e r o f t h i s c a r , some 1 8 m o n t h s b e f o r e t h e i m p o r t e d two
s e a t e r appeared on t h e American market.
FUTURE P L A N S c a l l f o r t h e d e v e l o p m e n t and i n t r o d u c t i o n o f JAMA1CA.N 11; a
body a n d f r a m e k i t u s i n g t h e JAMAICAkI V ~ / W W body s t y l i n g and a new f r a m e ,
u t i l i z i n g c o m p l e t e P i n t o d r i v e - t r a i n components, r a c k a n d p i n i o n s t e e r i n g
and a l l .
An e x c e l l a n t "ECONOMY" c a r .
THANK YOU FOR YOUR INTEREST I N OUR PRODUCTS!!
The management
FIBERFAB,
Inc.
Jan.
1974
P r i o r t o m o u n t i n g t h e m a i n body s e c t i o n t o t h e c h a s s i s / f r a m e ,
c u t o u t door openings,
a s well a s F r o n t a n d rear g l a s s o p e n i n g s , a s f o l l o w s :
1. U s i n g w i n d s h i e l d g l a s s a t m m p l a t e , p l a c e
C u t a l l o p e n i n g s w i t h s a b r e saw:
g l a s a i n r e c e s s e d area, c e n t e r from t o p t o b o t t o m a n d s i d e t o s i d e , u s i n g
small b l o c k s o f wood a t t h e b o t t o m o f g l a s s t o h o l d u p i n p l a c e .
mark a n a d d i t i o n a l l i n e 1/2" t o
S c r i b e o r m a r k o u t l i n e o f g l a s s a n d remove.
Cut on i n n e r marking, l e a v i n g a l i p
5/8" i n s i d e t h e o u t l i n e o f t h e g l a s s .
o n w h i c h g l a s s w i l l rest l a t e r when i n s t a l l e d w i t h BUTYL TAPE ( a v a i l a b l e f r o m
all local glass installers).
2.
3.
P l a c e rear q l a a s i n r e c e s s e d a r R a s o t h a t qao b e t w e e n g l a s s a n d e d g e o f body
are e q u a l a l l round.
mark body n l o n q e d q e o f g l a s s a n d remove g l a s s .
a.
I f u s i n g P o r s c h n rear window "H" r u b b e r t o i n s t a l l g l a s s , c u t o n mark.
b.
I f i n s t a l l i n g w i t h h u t y l t a p e ( a s w i t h w i n d s h i e l d m e t h o d ) mark a s s e c t i o n
l i n e i n s i d e and follow i n s t r u c t i o n s a s above f o r windshield cutout.
c.
I f u n d e c i d e d ~t t h i s t i m e , c u t a s f o r w i n d s h i ~ l dt y p e i n s t a l l a t i o n , a s m o r e
can be c u t later, p r i o r t o i n s t a l l a t i o n .
C u t o u t d o o r o p e n i n q s . Mark o p e n i n g s a s shown bmlosl a n d c u t .
Follow dimensions
g i v e n o r c u t h o l e 9msiller a s more c a n b e c u t when i n s t a l l i n g d o o r s .
REflEflBER: When m a k i n g a n y c u t s i n t h e b o d y , you c a n a l w a y s c u t m o r e , b u t o n c e you
h a v e c u t t o o much, i t i s d i f f i c u l t t o r e p a i r .
1
Cut o u t t r u n k o p e n i n g (VW e n g i n e access, i f b e i n g m o u n t i n g t o VW c h a s s i s ) a s p e r
below:
Note:
Cut on d o t t e d l i n e f o r V l ~ l c h a s s i s i n g t a l l a t i o n o r i f you do n o t
d e a i r e t o use t h i s a s you qas t a n k f i l l e r l o c a t i o n .
4
I
3 /&
I
3" Dl*. /:OLE I D T E A L 3
(03s f i l l e r l n c a t i n r )
71" D i n .
H o l a -ant.nrnr!
hnlp
h ~ l n , ,-,"
*
c
3/&
1
1
I
b
t
The main body can now he h o l t a r l t.n thn f r a m ~n r , r r l , ~ r l n n r ~ a n .
I f i n s t a l l i n g on t h n V\II f l n n r r t ~ ? . ~rqo ~ L I Qf t ~ h b - : ~f i - b ~ t
pan end t h e f i b ~ r o l a q s ?--!v.
I f i n s t a l l i n q o n A f r a m ~ . cut. !"Y?'
o f t h e frame where body w i l l r n s t .
strinn
B o l t body t o V W f l o o r o n n : srrnl,r hodv
ALWAYS use l a r Q 8 f l a t e blnnhers h ~ t c ~ t
of b o l t s o r screws
of
rzkkor
(\/\I'
ant!
i t n n j bFit\lrA~nthcl
Q~IIP
t n t h a t o p edqe
c , t i t c C o a r q v shoot.-matai scrnlllg.
mnt1ntir.n r ! a - - o ( f i h a r ? l a s 5 ) and heeds
t n cr3mo
a o m
w
.
DOORS, m o u n t i n q and assemkly:
Hardware:
Hinges ( 4 ) f o r F o r d 55-66-67
Mustang
. . . . CSZZ65;7RClOB
801 B
B l OB
J
L a t c h e s (,2 ). GM ' 6 5 t h r u ' 6 7 2-door sedan
S t r i k e r s t u d s ( 2 -j GM '65 t h r u ' 6 7 2 - d o o r sedan
.
Window g l a s s ( p a i r )
Window r i s e r
"
Window t r a c k s and ~ u i d ~
( osa i r )
Window c h a n n e l
Weatherstrio-door p l a q s
Window c h a n n e l r u b b e r
Extrusion (m-t.al )
W e e t h e r s t r i ~( r u h h n r c l ~ t r u s i n n )
Handles, l o c k 5 . mi3c.
f l i s c e l l a n s o u s g i z a n ~ t q .h o l t l .
\
\
~,larharq.
Vlrl Uarmann Ghia COUPE
off
Lay o u t t h e access h o l e c e n t e r s on t h e door l i n e r s a s p e r f i o . 9-2.
Using a
h o l e saw o r a d j u s t a b l e c u t t e r , c u t o u t h o l e s .
Cornolete t h e o b l o n ~h o l e
i n upper p a r t o f t h e p a n e l w i t h a saber saw.
43"
I
Surf ace
T H I S S I D E UP FOR LEFT DOOR:
TURN OVER FOR R I G H T DOOR.
Cutout Center
Along T h i s Line
LATCH ACCESS HOLE
I
FIGURE 9-4
-0I
112
1
J
\
1
Door S t r a p S l o t
@
--
s t r i k e r 8 S t u d Cutout
1 - 1 1 2 " L o n g b y 518" H i g h
--
1 - 3 1 8 " L o n g b y 3 / 4 " Wide
WINDOW MECHANISMS MOUNTING HOLES
FIGURE 9 - 5
PU SHBUTTON CUTOUT
TEMPLATE
FIGURE 9 - 7
FIGURE 9 - 6
NOTE:
This figure shows the driver's
door latch arm.
Passenger's door latch arm i s the mirror image.
Pushbutton
Latch mechanism
Steel tube
3''
od,
a"
i
Installation
--- - -
- -- - - - - - -
.
-------!
Weld rod to
tube.
.-
-
I
33"
1
I
I
1
Ii
IT
5/16-18 Nut
welded on end of rod
I
i
2"
I
I
I
i . L1
LATCH ARM
- 7
-
Figure 9-9
L
.
1
!
I
I
i
I
1
'
I
1
;
I
.
1
Cut d o o r l a t c h holes:
Lay o u t t h e f i v e h o l e 8 i n t h e r e a r f a c e o f e a c h d o o r a s
s p e c i f i e d i n f i g . 9-3 and d r i l l w i t h
bit.
Now t a k e t e m p l a t e , f i g . 9-4 a n d c u t o u t t h e f i v e l o c a t i n g h o l e s a n d t h e c e n t e r a s
illustrated.
Align template on t h e door using t h e f i v e h o l e s f o r l o c e t i o n and
s c r i b e t h e c e n t e r cut-out
c u t o u t t h e l a t c h h o l e s w i t h a s a b r e saw.
--
Lay o u t t h e s t r i k e r s t u d c u t - o u t a n d d o o r s t r a p h o l e s a s p e r f i g . 9-5 a n d c u t - o u t .
Cut h o l e e f o r puah b u t t o n s ( o b t a i n b u t t o n s from C h r y s l e r p r o d u c t t r u c k l i d , e a r l y 5 0 ' s )
a s p e r f i g . 9-6.
Next, c u t o u t t h e t e m p l a t e , f i g . 9-7, l o c a t e on d o o r a n d s c r i b e .
Cut o u t t h e r o u n d p o r t i o n o f t h e s h a p e a n d f i l e o u t r e m a i n d e r .
Note:
If you a r e g o i n g t o u s e h a n d l e e i n l i e u o f t h e b u t t o n s , t h e h o l e w i l l b e i n
t h e same l o c a t i o n b u t o f a d i f f e r e n t s h a p e .
D r i l l h o l e s t o L o c a t e w i n d o w mechanisms, f i g . 9-5
Fabricate latch plate (2) a s per fig.
approximately.
9-8.
Use 1 4 gauge s t e e l p l a t e o r 1/1611
Be s u r e t h e n o t c h i n t h e p l a t e l i n e s up w i t h t h e s t r i k e r
Bolt l a t c h e s t o plates.
stud catch i n t h e latch.
Now, b o l t p l a t e ( w i t h l a t o h ) t o t h e d o o r s .
F a b r i c a t e l a t c h a r m s a s p e r f i g . 9-9.
T h e s e arms a r e r e q u i r e d t o t r a n s m i t t h e
p u s h b u t t o n a c t i o n t o t h e l a t c h mechanism.
I n s t a l l i n t h e d o o r u s i n g $'I-20x2" o v a l h e a d b o l t t h r o u g h t h e r e m a i n i n g h o l e
n e x t t o t h e l a t c h p l a t e , m o u n t i n g t h e arm on t h e b o l t ( i n s i d e t h e d o o r ) a s p e r
S e c u r e w i t h )-20 s e l f lock n u t .
Do n o t o v e r - t i g h t e n s o t h a t t h e arm
f i g . 9-9.
i s no l o n g e r f r e e t o r o t a t e .
I n s t a l l push b u t t o n a s s e m b l i e s a s p e r f i g . 9-10.
a f t e r p a i n t i n t , i f you wish.
Pushbutton
J
T h i s s t e p may b e p o s t p o n e d u n t i l
Spacer
1
1-1/2" x 1-1/2" x .083
Square steel tubing
1 / 2 " long
F i g u r e 9-10
- 8 -
Retainer
7/8" l D
Speed nut
DOOR SLO'T WEATHER S T R I P
F I C U R E 9-1Y
Y2
1
~7~~$/16-14
Tap
7
1%
114" Steel S t r a p
I
S T R I K E K S T U D AND DOOR H I N G E
NUT P L A T E S
(12 EACH)
FIGURE 9-13
Spring
-4-
4
DOOR H I N G E L O C A T I O N
F I G U R E 9-12
Rocker
C. lnsert 1 / 4 " - 2 0 x 1" oval head TH P holts In each of the fotlr 1 / 4 " r e q ~ ~ l a t omro ~ t n t ~ nholes
q
i n the door I iners.
Place five 1 / 4 " f l a t washers on each of these bolts ( ~ n s i d r .the door) and 1,olt IIP the regulators.
D. Again, referring to Figure 9-11, tao the two holes i n each g u i d e h a c k to 5 / 1 6 " - 1 8 .
E,
lnsert a g u i d e h a c k i n each door, aqain making sure to have the left qu~de/track i n the left door.
F. Place a 5 / 1 6 " flat washer on a 5 / 1 6 " - 1 8 x 1" oval head T H P bolt, Insert In the ttooer quide/track mounting hole
i n the door liner, and engage threads (run bolt i n guide/Uack a few turns).
G?
Next, place a 5 / 1 6 " flat washer on a 5 1 1 6 ' - 1 8 x 2 - 1 '2" Ihcw hcad b r l t alld #t\cort In the lower q l ~ ~ d c / t r a c k
~ n o ~ l n t ~hole
n q In the door I ~ n e r . I f t l i ~ sh n l l 1 5 not threaded 311 !he way tn Ihc Ilcad, in11 wrll have to place 5 / 1 6 " flat
~ t he rtln dowti and t ~ q t ' t d~S~C~CiI I~~ Ctn
I Ythc I ~ r i ~111
r erther case, w ~ t hat least
washers on the bolt so that a n ~ can
one f l a t washer on, thread a 5 / 1 6 ' - 1 8 t i t ~ t on the bolt. 0 not t ~ q l i t c r l Now start thc holt In the lower threaded hnlc
In the q ~ ~ ~ d e / t r a c k .
S T E P TWELVE:
Hang the Doors
A . Set the doors i n place i n the body, pa*ilnq particular attention to f i t ~ t l t lrlan hclwcen donr and bod,!.
necessary to 111akesome minor clianqcs I ~thc
I
door edqe, e.g.
the fit, tap? inplace with several layers of masking tape.
, rotrtid~tirio f f t l l r
It viay be
Inwvr rear corncr. When <,ltisficd wtlll
6. Measure up from the top edqc of the rorker panel (lower edge of the door) h ' and 1 6 - 1 / 4 " on the body, 111stahead
of the front face of the door. These two points [nark the lower edqes of tho twn l i ~ n n c s .
C.
Now place the hinges (see F i q ~ l r e9 - 1 2 ) i n p o s i t ~ o nand mark the holes
011
Liotl~the door and body
D. D r i l l the holes, marked in the above step, i n the body, using a 3 / 8 " d r i l l h i t . Remember, yo11 are d r i l l i n g throuqh
two w a l l s of the steel tube bonded to the inside of the body.
E.
D r i l l out the holes i n the door with 7 / 1 6 " d r i l l bit.
F. B o l t up the hinges to the door ltstnq 7 / l b 1 ' - 1 4 x 1 - 1 / 2 " hex head bolts arid 7 . 1 6 " - 1 4 tapped n ~ r plates.
t
Sec
Figure 9 - 1 3 for nut plate dimensions.
G.
B o l t up the hinges (and door) to the body using 3 / 8 " - 1 6
nuts.
S T E P THIRTEEN:
x 3-1/2" hex head bolts, flat washers, lock washers and
Install the Door Slot Weatherstrip
A. Take 3 ft. of the outside weatherstr~o(rubber l i p type) and snip one end 2t thr: nlo~rntingflanqe every 1/2" for
about 6 inches along the strip. Now hend very carefully to match the contn~lrill t l l ~rear of the slot i n the top of the
door. Position the strip i n the slot and rnark at the front end of the slot. Cut oH the excess weatherstrip.
6. Fasten weatherstrip to outside edoe of door s l o t flange w i t h 1 / 8 " x 1 / 2 "
Figure 9 - 1 4 .
C.
Perform the same operation d e s c r ~ b c dabove Irl A.
lion
rivets every 4 " along the strip.
See
using the insidt, w r ~ ; l t ' ~ ~ r s t(felt)
r ~ p on the inside edqe of the slot.
D. Fasten the f e l t weatherstrtp to thc i115idedoor slot flange with t n n t a r !
;r8 .rnt
S T E P FOLIRTEEN: Install the Door Windows
A: Mount a r u b h m o m m e t and glass holder on each window, b e ~ n qc ; v c f ~ ~tol allot1 tlic holes.
holders s h o ~ ~ be
l d on the concave side (inside) of the qlass.
The nuts o n the cllass
t the qlass to the inside of thc car) : h r s ~ ~ rt ~l ~l i window
'
slnt
B. lnsert the glass (concave s ~ d of
C.
B o l t glass holder to guide/track ~ ~ s i ntwo
q 1 / 4 " - 2 0 x 1" hex head holts, f l a t washers, luck waqhers and Teflon n ~ t t s
i n the top holes and two 6mm x l O m m bolts, f l a t washers and lock washers ~n the bottom holes. Do not tighten.
S T E P F I F T E E N : A l i g n the Doors
A. The additional weight of the qlass in the doors may cause a requirement for the re-aliqnment of the doors on their hinqeq
I f t h i s be the case, you w i l l have to determine i n which direction the hinqes w ~ l have
l
to be moved, reniove the hinqes, and
elongate the appropriate holes i n the correct direction.
S T E P S I X T E E N : Install S t r i k r r S t t ~ d s
A. Place a piece of crayon, markinq pen or oencil i n the striker stud socket In the latch mechanism. Now close the door
carefully, adjusting the marker so that i t scribes the mating surface o f thc hndv. The end of this scribe line locates t h r
striker stud.
d
and Insert a strlkcr s t ~ d . Fasten w ~ t ha 7 / 1 6 " - 1 4 tapped
R . D r i l l a 7 '16" holp at ttlr l n c a t ~ n n~ d r n t i f ~ eabove
<LriCt>r stud nut plate.
S T E P SCVE 4TEEN: A l i n n tlie Glass
r .loor c l r \ , d , ad111stthe w ~ d n w
h e ~ q h ta d fore a d aft p o s ~ t ~ o(1~11I1ztnq
n
the w l n d w crank a d thc slots
A :$IUI'
~ n edqe of the qlass a d the
tr ~ h c~ l a s s / ~ l o~l +r / q l tde) for an r v p n l y d ~ s t r l b u l e dgap of 3/4" (t 1/8' b t w ~ the
\ r r ~ ~ ~ dOo~wV I I I 11, In the t,ody. When t h ~ sal~qnmentIS s a t ~ s f a c t o r y , t ~ q h t ~the
n qlass holder bits a d adjust the l i m i t
a t l l ~ ~ r t n l e nI,(,lt
f
( F I ~ I I ~ 9I - 1 1 ) slid l o r k d n w ~w ~l t h Lhc lock nut.
-11
--
I n s t a l l i n g t h e r e a r deck l i d i s s i m p l i f i e d by u s i n g exposed chrome hinges,
a s t h o s e found on a " S p i t f i r e " o r s i m i l a r car.
mounting t h i s
A s i m p l e l a t c h i s t h e VW r e a r engine l i d push-button type.
on t h e r e a r deck and a t t a c h e d a m e t a l c a t c h t o t h e body i s s u f f i c i e n t .
Hidden l a t c h e s w i t h c a b l e c o n t r o l l e d r e l e a s e i s a l s o e a s i l y i n s t a l l e d .
NOUNTING THE FRONT SECTION OF THE BODY:
Cut o u t t h e g r i l l e and hood openings w i t h a sabre saw.
Sand t h e edges smooth and s t r a i g h t .
See f i g .
10
Lh
F i g u r e 10-1
1
-c u t along t h i s l i n e
I
r".)
+-~*JT
HOOD OPENING
10-1.
INSTALLING THE HEADLIGHTS:
U s i n g t h e t e m p l a t e below ( f i g . 10-2) and p o s i t i o n i n t h e h e a d l i g h t t u n n e l .
Template s h o u l d be c e n t e r e d s i d e - t o - s i d e and down 5/8" f r o m t h e t o p edge
o f the tunnel.
S c r i b e t h e c i r c l e and c u t o u t w i t h saw.
Sand and n o t c h f o r a d j u s t i n g screws.
We have f o u n d t h e most d e s i r a b l e h e a d l i g h t assembly t o use i s t h e CORVAN.
Many o t h e r type, s i n g l e h e a d l i g h t a s s e m b 1 . e ~ w i t h ? " d u a l beam a r e usable.
Mount h e a d l i g h t f r o m
VW h e a d l i g h t b u c k e t s ( ' 6 7 o r newer) a r e a l s o u s a b l e .
b e h i n d opening, a l l o w i n g chrome t r i m t o ccme througt- h e a e l i g h h o l e . S m a l l
washers may be n o c e s s a r y t o space h e a d l i g h t assembly t o d e s i r e d p o o i t i o n .
Meadlight template
f i g u r e 1@-7
CUTOUT
TEMPLATE
FIGURE
-
15-
8-3
Front parking/directional lights should be installed at this time, a s
well a s side lights, if desired or required by state laws.
Cut out the tail light installation holes, a s per template fig. 8-3.
The body was designed for the installation of Plaverick/Pinto
assemblies.
Drill the stud holes with a
with a sabre saw.
Install tail-light units.
flOUNT
THE
FRONT-END
ON
t" drill
tail light
bit and cut out the elongated holes
Install rear side lights (if desired).
CHASSIS:
Note: Installation a s described is for frame mourting.
will be used for VW installation.
Similar mounting
Inner panels in nose of VW will be mounted to frame rails (supplied with
VW kit) by using sheet metal screws and large flat washers.
A . Tape the edge of the body (up the l e f t rocker, left door, across the cowl and down the right side) where the front
end meets the body w i t h 3/4" masking tape. One edge of the tape should be exactly at the edge of the body panels.
8. Place the front end on the chassis and center from side-to-side. Place a straight edge on the accent crease i n
the center of the doors and position the front end such that the same crease i n the front end i s parallel w i t h straight
edge.
C. Tape the edge of the front end with 3/4" masking such that i t i s directly over the tape on the body. T h i s w i l l
define the actual finished edge of the front end.
0. Cut the excess off the front end with a sabre saw, by cutting along the tape edge. Sand smooth.
E. Re-position the front end and check alignment.
panel.
Shim, i f necessary, between the frame and the front end inner
F. D r i l l two 1/4" holes through the front end and the cowl at the locations shown i n Figure 1 0 - 1 , and fasten with
1 / 4 " - 2 0 x 1" oval head T H P bolts, f l a t washers, lock washers and nuts.
G. Locate the conical boss i n the inner panels near the front end of the frame and d r i l l a 1/4" hole through the frame
and through the center of this landing. Fasten with 1 / 4 " - 2 0 x 6" hex head bolts, flat washers, lock washers and nuts.
H. D r i l l a 5/16" hole through the rocker panel section of the front end just ahead of the joint w i t h the body. D r i l l
through the body panel behind the rocker. Insert a 5 / 1 6 " - 1 8 x 1 - 1 / 2 " carriage bolt i n the hole. Place a sufficient
number of 5/16" flat washers on the bolt to shim the front end section of the rocker out to the body section and fasten
w i t h a f l a t washer, lock washer and nut.
I. Fasten the front end inner panel to the sides of the frame members with 3 / 1 6 " x 1 - 1 / 2 " sheet metal screws and
wide area washers.
INSTALLING THE
HOOD:
Hinges (pair) Stingray, Chevrolet #3912639 and 3912640
Telescoping hood support (stingray)
Hood latch assembly a at sun); mercury latch; external hood pins
Installing the hood (continued):
Place the hood in position in the opening in the front end and determine
what edge sanding, if any, must be done. NOTE: The shape of the opening
in the front end may vary a small amount between different installations,
due to the varying procedures for attaching the front end to the body and
chassis. Sand edges where necessary. proceed to hinge:
-
STEP THREE: Install the Hinqcs
A . Place the hinges on the liinqe rnocrntinq bosses (rarsed sllrfaces 011rlthcr srdc and toward the front of the hood
liner), s ~ c hthat the hinge pin is 011the outside of the boss and closc to the liner sclrface with the larger of the hinqe
flanges on the boss and all tlle way :o tile rear edqc of the boss.
B. Drill the holes through the boss ant1 thc stccl plates bonded to tiler11 with a * I 0 drill and tap to 1 / 4 " - 2 0 .
C. Bolt on the hinges with 1 / 4 " - 2 0 x 1" hex head bolts, flat washers and lock washers.
D. Drill 2 c ~ c l 1i / 4 " lioles i r r nriv Icq of c a c l ~2" x 2 " x 1 / 6 " x 4 " anqlc for attachment to hood inner panels.
E. With the front of the car up on jack stands, place the hood i n position, reach up between the nose and radiator,
place the angles in position between tlie inner panel and hinqe flanqe, and mark the hole locations (angles-to-inner
panel and hinqe-to-angle).
F.
Remove hood and drill 1 / 4 " lioles at the markinqs.
G . Bolt the angle brackets to the inner panels with 1 / 4 " - 2 0 x 1" hex head bolts, flat washers, lock washers and nuts.
x 1" hex head bolts, flat washers, lock washers
H. With the hood vertical, bolt the hinges to the brackets with 11'4"-20
and nuts.
STEP FOUR: lnstall the Hood Support
A. Position the telescoping hood support with its mounting bracket under the hood opening l i p 7 - 3 / 4 " back (toward the
windshield) from the hinge bracket, measured ivot-to- Ivot.
Mark and d r i l l two 1 / 4 " holes and bolt up with two
1 / 4 " - 2 0 x 1" oval head TH P bolts, flat wasRrs, olc!
washws and nuts.
B.
Position the upper support bracket on the mounting boss section of the hood liner and m a k the mounting hole
locations.
C. Drill two holes in the liner with a Y 1 0 drill bit and tap to 1/411-20.
D.
Bolt the support bracket to the hood liner with two 1/411-20 x 3 / 4 " hex head bolts, f l a t washers and lock washers.
S T E P FIVE: lnstall the Hood Latch Assembly
A. Position the latch pin assembly on the hood liner boss (located off-center at the rear edqe of the hood) and mark
the pin bolt clearance hole and the two mounting holes.
0.
D r i l l the clearance hole with a 5/8" drill.
C. Drill and tap (1/4Ir-20) the two mounting holes.
D. Bolt the latch pin assembly t o the hood with 1/411-20 x l " hex head bolts, flat washers and nuts.
S T E P SIX: Install the Latch Assembly
A. With the hood down and the latch pin rest ng on the cowl, m a k the center of the center of the latch pin on the
cowl.
B. D r i l l a 1-1/2" hole through the cowl section of the front end.
C. Place the latch assembly in position and measure the distance from the latch mounting holes to the firewall.
Transfer these measurements to the two pieccs of 1- 1/2" x 1-1/2" steel angle and drill two 1 / 4 " holes. D r i l l two
1 / 4 " holes i n the other leg of the angle.
D. &It the angles to the latch assembly.
E. Position the latch assembly and mark the mounting hole locations on the firewall.
F . Drill two 1 / 4 " holes and attach the latch assembly with 1 / 4 " - 2 0
and nuts.
S T E PSEVEN:
-
x 1" hex head bolts, flat w a s h ~ r s ,lock W I - ! ' r r c
Install the Hood Release Lever
A . F ild a convenient location on the square tube crossmember under the dash, position the lever assembly, mark and
drill the mounting holes.
B.
Fasten the lever assembly with 3 / 1 6 " sheet metal screws and flat washers.
C. Route the cable from the lever through the firewall to the latch.
INSTALLING HEADLINER AND PlOULDING TRIPl CLIPS:
The f i v e p i e c e s o f w i n d s h i e l d t r i m m o u l d i n g ( c o r v e t t e ' € 1 3 - ' € 1 7 ) ~r e q u i r e a
You w i l l f i n d i n d e n t a t i o n s
t o t a l o f 17 c l i p s ( 2 c o r n e r s a n d 1 5 s t r a i g h t ) .
a r o u n d t h e edge o f t h e w i n d s h i e l d o p e n i n g f o r t h e s e c l i p s .
P o s i t i o n t h e c o r n e r c l i p s i n t h e u p p e r c o r n e r i n d e n t a t i o n s , a l l t h e way down
C e n t e r i n t h e c u r v e and d r i l l a n
so t h a t t h e y bottom i n t h e i n d e n t a t i o n s .
Insert
1/8" h o l e t h r o u g h t h e f i b e r g l a s s a t e a c h m o u n t i n g h o l e i n t h e c l i p .
Repeat f o r t h e r e m a i n i n g 15 c l i p s .
a p o p - r i v e t and s e t .
I n s t a l l i n g headliner material:
A f t e r a l i g h t s a n d i n g o f t h e i n n e r r o o f , a p p l y c o n t a c t cement ( 3 M w e a t h e r s t r i p adhesive i s e x c e l l a n t t o u s e ) i n s i d e r o o f , around windshield, r e a r
window and d o o r f l a n g e s and down t h e w i n d s h i e l d p o s t s .
Have r e a d y ,
h e a d l i n e r m a t e r i a l t o be used:
1 p i e c e b011x471', 2 s t r i p s 7 " ~ 2 0 " .
A p p l y c o n t a c t cement t o t h e back s i d e o f t h e t h r e e p i e c e s o f m a t e r i a l .
When a l l cement i s t a c k - f r e e ,
f o l d t h e l a r g e p i e c e i n h a l f (40" x 233"w i t h t h e cement o u t and p l a c e t h e f o l d e d edge a g a i n s t t h e r o o f , c e n t e r e d b o t h
f r o m a i d e - t o - s i d e and between t h e s i n d s h i e l d and r e a r window o p e n i n g s .
Now smooth o u t t h e m a t e r i a l a g a i n s t t h e r o o f , w o r k i n g f r o m t h e c e n t e r o u t t o
t h e d o o r openinga.
Wrap t h e m a t e r i a l a r o u n d t h e d o o r and window f l a n g e s and
t r i m excess w i t h a r a z o r l e a v i n g a t l e a s t
o f m a t e r i a l wrapped a r o u n d
t h e flanges.
3"
F o l d a n end o f t h e r e m a i n i n g p i e c e s o f m a t e r i a l b a c k o n t h e m s e l v e s
(cement
t o cement) end p r e s s t o g e t h e r .
Place these pieces over t h e w i n d s h i e l d posts,
w i t h t h e f o l d e d edge n e a r t h e t o p o f t h e p o s t .
Ift h e s e p i e c e s o v e r l a p
t h e i n = p l a c e l i n e r , a p p l y cement t o t h e h e a d l i n e r and l e t d r y b e f o r e g l u i n g
t h e post covering i n place.
Wrap a r o u n d f l a n g e s and t r i m o f f t h e excess.
ASSEmBLE AND INSTALL DASH:
The i n s t r u m e n t s and s w i t c h e s a r e most e a s i l y i n s t a l l e d i n t h e d a s h b o a r d bef o r e t h e d a s h b o a r d i s p e r m a n e n t l y mounted i n t h e body.
Therefore, s e l e c t i o n
o f gauges and s w i t c h e e s h o u l d be a n t i c i p a t e d a t t h i s t i m e .
We have f o u n d i t e a s i e r t o i n s t a l l t h e w i p e r assembly p r i o r t o i n s t a l l a t i o n
o f t h e dash.
WINDSHIELD WIPER ASSEmBLY:
Parts:
Wiper motor ( c o r v e t t e , P i n t o o r American Bosch WWC 12-612s)
Bracket
f a b r i c a t e d f r o m 14 gauge o r 1/16" s t e e l p l a t e
P i v o t Shafts (2)
Gasket, washer n u t f o r s h a f t s
D r i v e A r m ( 1 ) C o r v e t t e , P i n t o o r Am. Eosch LE 721124A
Drive l i n k s (2) "
II
"
LK721031**
Wiper Arms ( 2 )
TRICO a d j u s t a b l e AL-225
RE-1 4"
Wiper b l a d e s . ( 2 )
Cap screws ( 3 )
$"x28x3"
B o l t w/lock n u t s ( 4 ) $11x20
-
L o c a t e t h e h o l e s f o r t h e P i v o t s h a f t s 3/41' below w i n d s h i e l d o p e n i n g a s
p e r f i g . 8-5 below.
Figure
8
8-5
PIVOT
SH4FT.S
P i v o t S h a f t s ( 2 ) e x t e n d t h r o u g h body, a s above.
a t t a c h e d t o s p l i n e d ends o u t s i d e body.
Wiper arms and b l a d e s a r e
IMPORTANT: The i n n e r p a r t o f p i v o t s h a f t s ( b r a c k e t t o which d r i v e l i n k s a r e
a t t a c h e d ) must be p o s i t i o n e d so t h a t one b r a c k e t i s upward, t h e o t h e r downward, so t h a t b l a d e s w i l l wipe t o w a r d each o t h e r , p a r k i n g so t h a t t h e ends
o f blades a r e a t center o f windshield.
Motor can be mounted o f f t o one s i d e , c e n t e r ; o r o f f c e n t e r .
I f motor i s
p o s i t i o n e d t o one s i d e , t h e f i r s t d r i v e l i n k w i l l connect t h e d r i v e - a r m t o
The second d r i v e l i n k w i l l c o n n e c t t h e two
the neargst p i v o t s h a f t bracket.
pivots. '
W i t h m o t o r c e n t e r e d , e q u a l l e n g t h d r i v e l i n k s w i l l b o t h be p l a c e d on d r i v e arm
and e x t e n d t o each p i v o t s h a f t .
I f m o t o r i s o f f - c e n t e r , b u t between p i v o t
s h a f t s , d r i v e l i n k s w i l l b o t h be p l a c e d on drive-arm, however, l i n k s w i l l be
o f unequal length.
B r a c k e t s h o u l d be f a b r i c a t e d t o s u p p o r t motor i n a f i r m p o s i t i o n ,
l o c a t i o n under dash.
a f t e r selecting
DASHBOARD PREPARATION AND INSTALLATION:
The d a s h b o a r d s h o u l d b e p r e p a r e d b e f o r e any i n s t r u m e n t s o r s w i t c h e s i s mounted.
L a y o u t t h e i n s t r u m e n t s and s w i t c h e s on t h a dash panel...We
o u t below, f i g . 8-12.
recommend t h e l a y -
RIGHT TURN
TND~CATORLIGHT
SPEEDOMETER
TACHOMETER
F i g u r e 8-12
U s i n g t h e 3 1/8" h o l e saw, a n d t h e 2 1/6" h o l e saw o r a n a d j u s t a b l e d r i l l - b i t
c u t t e r , d r i l l o u t t h e h o l e s f o r gauges a n d mount gauges.
D r i l l h o l e s f o r s w i t c h e s a n d mount.
I f t h e d a s h i s t o be p a i n t e d , s a n d a l l
When d r y , west
h o l e s , sand f u r f a c e t h e 8120 g r i t , s p r a y p r i m e r o n t h e dash.
s a n d w i t h #240 g r i t .
When s u r f a c e i s smooth and d r y , s p r a y e n t i r e d a s h w i t h
lacquer.
Check d a s h b o a r d f o r f i t i n p l a c e , l a y i n g t h e f o r w a r d p o r t i o n o f t h e dash,
o v e r t h e l i p i n t h e body b e h i n d t h e w i n d s h i e l d o p e n i n g .
Be s u r e t h a t t h e t w o dash c o r n e r do n o t e x t e n d beyond t h e d o o r o p e n i n g s .
A f t e r you a r e s a t i s f i e d w i t h f i t , proceed as f o l l o w s :
F i r s t , l a y u p a good b o n d i n g a g e n t ( o r f i b e r g l a s s r e s i n / h a r d e n e r / m a t t i n g )
o n l i p o f body a n d p l a c e dash o n i t , w e i g h t i n g i t down f i r m l y .
Pop r i v e t s
may b e u s e d i f d e s i r e d .
U s i n g a "Bondo" t y p e body f i l l e r , t h e f o r w a r d edge o f dash may be b l e n d e d
i n t o body and f r o n t edge b e h i n d w i n d s h i e l d o p e n i n g .
I f padding i s desired,
i t i s n o t necessary t o use f i l l :
(a"
Lay f o r m
o r 3 " ) o v e r t h e dash a l l o w i n g i t t o d r a p e o v e r i n n e d edge
s u f f i c i e n t l y t o c o v e r t h e a r e a y o u d e s i r e t o pad.
T r i m t o f i t a n d bond t o
dash.
Lay v i n y l o v e r foam i n t h e same manner.
However, a l l o w t h e v i n y l
Bond t h e p o r t i o n
t o e x t e n d i n t o t h e s i n d s h i e l d s u p p o r t i n g l i p a b o u t 3/811.
o f t h e f i n y l u n d e r t h e i n s i d e edge o f d a s h a n d a l o n g p r o t r u d i n g i n n e r edge
o f dash.
F u r t h e r s e c u r e t h e l o w e r edge w i t h a m e t a l t r i m s t i p (aluminum).
Draw v i n y l t i g h t o v e r foam t o w a r d w i n d s h i e l d s u p p o r t i n g 'lip,
o v e r edge a n d
s e c u r e i n p l a c e w i t h a good g o n d i n g a g e n t .
( 3 W
~ eatherstrip adhesive).
Trim
DEFoGGER/DEFRoSTER INSTALLATION:
F i b e r f a b o f f e r s a defogger k i t c o n s i s t i n g o f t h e f o l l o w i n g :
1
2
-
12 v o l t blower motor
g r i l l e s f o r dash
B l o w e r Hose
The f o l l o w i n g i n s t a l l a t i o n c o v e r s t h i s u n i t ,
a l s o used u n i t s from C o r v a i r s , etc.
however,
c u s t o m e r s have
I n t h e Jamaican V8 assembly, t h e d e f o g g e r can be used i n c o n j u n c t i o n
w i t h a h e a t e r c o r e , u s i n g t h e b l o w e r t o c i r c u l a t e warm a i r f r o m t h e
c o r e up t h r o u g h t h e d e f o g g e r v e n t s .
T h i s i s an e x c e l l a n t combination
h e a t e r / d e f r o s t e r set-up.
I n t h e JAMAICAN VW a p p l i c a t i o n , t h e b l o w e r w i l l c i r c u l a t e i n t e r i o r
warm a i r f r o m t h e h e a t i n g system u s i n g t h e VW h e a t boxes, e t c .
The d e f o g g e r s h o u l d be i n s t a l l e d a f t e r t h e dashboard i s i n s t a l l e d i n
t h e body
b u t b e f o r e t h e s i n d s h i e l d and p a d d i n g ( i f a n y ) a r e p e r manetly placed.
--
Blower motor -
Washer & nut
o r CflU
3?ii
Bulkhead
FIGURE 1.
View from the top of the windshield as i f standing
on the top of the car.
FIGURE 2 .
Grille
Padded dash
+-Fiberglass
dash
DEFOGGER K I T I N S T A L L A T I O N INSTRUCTIONS
Instal lation of Defosser K i t
Start by placing the template provided in the upper right corner of the forward bulkhead (firewall
i n front engine bodies) as shown i l l Photo C . Tape or g l ~ r etemplate to bulkhead in proper position
and using the 3 " hole saw d r i l l through template where blower motor hole is marked. F i l e a small
notch as shown on template. Using the 1 / 4 " d r i l l b i t d r i l l throlrgh the template where 1 / 4 "
mounting holes are marked. Rcniovc template.
To mount blower motor unit place the motor through the 3" hole i n bulkhead. Be certain the two
wires (one wire is to be connected to the chassis ground system and the other to a source of
switched - 1 2 V ) remain cjn the cockpit side of the bulkhead -- the f i l e d notch is where they
return through the b ~ ~ l k h e ainto
d the cockpit area. See Figure 1 on Page 3 . S f ,Ire unit with
1/4"-20 hardware. Put sealant around motor as it projects into tlie gas tank u l L d -- do not put
sealant around motor i n cockpit area.
,
To install blower grilles -- locate g r i l l e duct o ~ r t l e t son the top of the dashboard as shown i n
t
dash between the lower, outside corners of the
Figure 2 on Page 3 . Draw a I ~ n cs t r a ~ g l ~across
windshield opening ( @ i n Figure 2 ) . Measure 16-1/4" from each corner @ and draw a line
i n Figure 2). Then measure 1" from line @ toward hood and draw a l i n e ( 0 i n Fiqure 2)
(
that w i l l intersect line @.
The point where @ and CJinli:rsect is the center OF the g r i l l e hole. D r i l l 3" hole with the hole
saw for each g r i l l e duct. I f padded dash is to be installed, d r i l l holes before i n s t a l l i n g padded
dash, but inset the grilles after installing padded dash. (Use a razor blade and cut a 2-1/2" +
i n the padded dash in the center of the 3" g r i l l e hole). Insert g r i l l e duct into holes i n dash.
Place U-brackets over plastic studs then use the self-threading Tinnerman nuts to secure. See
Figure 3 on Page 3.
Measure and cut the proper length of blower hose needed to get from motor unit to each g r i l l e duct.
-- no clamps are necessary to
hold hoses i n place.
To attach hose just slide hose over nozzles of the blower and g r i l l e
Location for template
marking mounting holes
for blower motor unit.
Note:
Pictured
from i n s i d e o f c a r ,
p a s s e n g e r s i d e of
cockpit, before
d a s h b o a r d i s mountcd.
UPHOLSTERY
-
INTERIOR FINISHING
The u p h o l s t e r i n g o f your GT i s p u r e l y a m a t t e r o f p e r s o n a l
You can b e a s a u s t & e o r a s e l a b o r a t e a s you d e s i r e ,
taste.
p u r e l y f u n c t i o n a l f o r t h e " r o a d machine" b u f f o r posh f o r t h e
grand t o u r i n g e n t h u s i a s t .
A t t h e f a c t o r y , we u s e t h e GT u p h o l s t e r y k i t a v a i l a b l e from
.
F i b e r f a b ( a s an a c c e s s o r y k i t , a t e x t r a c o s t )
Fiberfab's
u p h o l s t e r y k i t c o n s i s t s o f automotive-grade c a r p e t s , c u t t o
f i t and bound.
I t a l s o i n c l u d e s t h e h e a d l i n e r , v i n y l door
p a n e l s , s e a t c o v e r s , t r i m screws and a q u a r t o f a d h e s i v e .
I f you have a c c e s s t o a commercial, heavy-duty machine you can
make your own c a r p e t i n g and i n t e r i o r t r i m .
The m a t e r i a l s r e q u i r e d
are:
6 y a r d s v i n y l - - 1 2 y a r d s c a r p e t i n g ( 3 6 " wide) - - j u t e
padding, c a r p e t b i n d i n g , a d h e s i v e and t r i m screws.
I
,
,
Use heavy paper t o make p a t t e r n s o f t h e i n t e r i o r s u r f a c e s o f t h e
car.
T r a n s f e r t h i s p a t t e r n t o t h e c a r p e t (making s u r e it i s n o t
upside-down) and c u t .
Sew on b i n d i n g .
The same " p a t t e r n " t e c h n i q u e i s used t o develop door p a n e l s , c o n s t r u c t e d o f v i n y l sewn
t o panel-board.
A c u s t o m i z i n g e f f e c t can b e g a i n e d b y sandwichi n g up t o 1" foam r u b b e r s h e e t between t h e v i n y l and panel-board
and t h e n s t i t c h i n g a d e s i g n i n t h e v i n y l .
I
Before i n s t a l l i n g t h e c a r p e t s , h e a d l i n e r , e t c . , rough-up t h e
f i b e r g l a s s s u r f a c e s t o b e covered w i t h any c o a r s e sand p a p e r .
A f t e r sanding, wipe t h e s u r f a c e s w i t h l a c q u e r t h i n n e r o r a c e t o n e .
When s u r f a c e s a r e p r e p a r e d , c o a t them t h i c k l y w i t h a d h e s i v e - a l s o
c o a t t h e back s i d e o f t h e c a r p e t , e t c . When t h e a d h e s i v e i s t a c k y ,
i n s t a l l the carpet.
Door p a n e l s may b e g l u e d i n p l a c e , o r a t t a c h e d
w i t h t r i m screws.
Other i t e m s t o b e c o n s i d e r e d f o r i n t e r i o r f i n i s h i n g i n c l u d e asht r a y s m ~ u n t e di n t h e c o n s o l e , i n t e r i o r l i g h t s mounted b e h i n d t h e
window openings, e t c .
LET YOUR IMAGINATION BE YOUR G U I D E 1 1 !1
I n s t a l l t h e FRONT and REAR Windows:
To i n s t a l l t h e g l a s s , you w i l l need t h e f o l l o w i n g (can be purchaeed f r o m l o c a l
auto glass i n s t a l l e r s ) .
C a u l k i n g gun
1 box PTI Auto Tape K i t 5/16" R103 B u t y l Tape
1 t u b e s i l i c o n e r u b b e r w i n d s h i e l d s e a l e r ( c a u l k i n g gun s i z e )
15 f t . s t o u t c o r d ( f o r r e a r g l a s s i n s t a l l a t i G n )
1 qt. solvent
1 163-167 C o r v e t t e S t i n g r a y coupe w i n d s h i e l d g l a s s and t r i m m o u l d i n g s , - c l i p s
1 Porsche 911/912 r e a r window
1 Porsche "
"
r e a r window r u b b e r ( g a s k e t )
1 s e t Porsche r e a r window chrome t r i m .
B e f o r e proceeding, note:
Once t h e windows have been i n s t a l l e d , i n s t a l l a t i o n
o f a h e a d l i n e r and padded dash c o v e r a r e d i f f i c u l t , these should be done
p r i o r t o window i n s t a l l a t i o n .
P l a c e p i e c e s o f masking t a p e on t h e body ( o r marks) n e x t t o t h e moulding
A.
c l i p s so you w i l l be a b l e t o f i n d them when i n s t a l l i n g t h e chrome t r i m .
P l a c e t h e PTI t a p e around t h e w i n d s h i e l d opening about 1/16'
8.
edge o f t h e l i p ' ( i n n e r edge).
C.
i n from t h e
Apply s i l i c o n e s e a l e r between t h e PTI t a p e and t h e outer-edge of t h e l i p .
0.
P l a c e t h e g l a s s s q u a r e l y i n t h e c e n t e r o f t h e opening.
i s a two man job.
Be c a r e f u l , t h i s
E.
Apply more s e a l e r between t h e edge o f t h e g l a s s and t h e edge o f t h e ' w i n d s h i e l d opening.
Insert the
INSTALL CHRONE TRIN:
S t a r t w i t h the lower l e f t s e c t i o n o f t r i m .
mounting f l a n g e on t h e ' c h r o m e , b e t w e e n t h e c l i p and t h e f i b e r g l a s s and push
DO NOT USE ANYTHING BUT YOUR HANDS o r you may
down u n t i l i t c l i c k s i n place.
dent the t r i m .
F o l l o w t h e same procedure w i t h t h e r e s t o f t h e t r i m ; l o w e r r i g h t s e c t i o n ,
upper s e c t i o n , upper l e f t c o r n e r , upper r i g h t corner.
Wash o f f excess s i l i c o n e s e a l e r w i t h s o l v e n t .
INSTALLING
A.
REAR WINDOW?
Place t h e r u b b e r grommet around t h e g l a s s as shown i n F i g .
9-17.
8.
I n s e r t t h e aluminum t r i m mounting f l a n g e i n s l o t i n grommet.
S l i p the
c o n n e c t i n g c l i p s o v e r t h e f i r s t h a l f b e f o r e i n s t a l l i n g second h a l f .
C.
You
the
top
I n s e r t s t o u t c o r d i n t h e body-mounting s l o t i n t h e grommet (gasket).
w i l l f i n d i n s t a l l a t i o n much e a s i e r i T you use two p i e c e s o f cord, from
t o p c e n t e r t o bottom c e n t e r , l e f t and r i g h t .
Overlap t h e c o r d s a t t h e
and bottom s l i g h t l y .
0.
P l a c e t h e window s q u a r e l y i n t h e c e n t e r o f t h e opening.
This also i s a
two man o p e r a t i o n .
One man o u t s i d e p u s h i n g down on t h e g l a s s , w h i l e t h e
second man p u l l s t h e c o r d f r o m i n s i d e as shown i n f i g . 9-10.
Pull, t h e c o r d o u t about 6" t o p and bottom, on t h e l e f t s i d e and t h e n t h e
E.
Repeat t h i s o p e r a t i o n u n t i l gasket i s s e t a l l t h e
same on t h e r i g h t s i d e .
way around.
After f i t t i n g trunk l i d ,
i n s t a l l w i t h h i n g e s and
latches.
-
:
The V W r e a r l a t c h may b e
' y s e d i n c o n j u n c t i o n with,:
-latch plate similar to
f i g . 9-16, r i g h t .
H i n g e s may be e x p o s e d f o r
e a s e of assembly, using
r e a r h i n g e s o f f TR, S p i t f i r e , etc.
..
.
LOCK a ~ T C H TEMPLATE
FIGURE 9-i6
/
Glass
Aluminum T r i m
w
REAR WINDOW I N S T A L L A T I O N
F I G U R E 9-17
Glass
Body
R E A R WINDOW IN S T A L L A T I O N
F I G U R E 9-18