SECTION D - BODY/CHASSIS ASSEMBLY
67
BODY MOUNTING
Preparation Is Everything! Before starting, have all tools
and materials ready and read the text below.
All the aluminum splash and trunk panels must be
removed before the body shell is installed. Once the body
is bonded at the areas indicated (except for the nose
opening), the front inner panels must be installed in the
pre-drilled holes to locate the nose support bar.
Clean and rough the tops of the chassis at the areas
indicated.
Remove the front body mount.
With assistance, raise the body over the chassis. Lower
the front so that the bottom lip goes over the front chassis
horns.
Carefully spread the body sides while slipping the lower
body edges over the cowl support side tubes. Lower the
body down over the cowl supports and onto the chassis.
Use small blocks of wood, etc. to keep the body at least 2"
above the bonding strips and chassis.
Loosely install the front body mount.
Attach the aluminum front wheelhouse panels to the body
tube, either with several Clecos©, rivets or small screws.
When the body is lowered, the bottom holes in the
aluminum must line up with the holes in the chassis.
Mix a trial batch of bonding adhesive (see “Supplies and
Materials" on page 30) to check the set-up time before you
start. You must have enough time to apply the adhesive
and carry out the all the subsequent installation steps
before hardening. Use less catalyst or hardener to increase
working time.
Use a caulking gun to apply body sealant (also used on the
floors and foot boxes) to the chassis and corresponding
body parts except:
The bonding strips
The rocker panel longitudinal mounting tubes
Edges of the upper trunk panel that the body will
contact.
Apply the bonding adhesive between the surfaces
indicated on the diagram.
Remove the spacer blocks between the body and chassis,
lining up the original screw holes used for shipping.
Refasten the rocker panels, firewall, front cowl and nose-
opening supports and the intermediate support on the rear
crossmember.
While the adhesive is still soft, install the front inner
splash panels with a few rivets or screws to establish the
front body height. See page 58 for details.
Install the nose support to establish the left/right location
for front body
Smooth out any excess sealant, at the same time sealing
gaps where water and dirt could accumulate. Wipe off
excess bonding material from all joints, and clean up with
lacquer thinner or acetone, taking extra care near painted
surfaces.
Use
1
/
8
" aluminum or stainless steel blind rivets to
complete the body attachment. Drill
9
/
64
" holes through the
guide holes in the following panels into the chassis, and
rivet body to the chassis:
Front inner wheel house panels (
1
/
8
" rivets) and the
triangulated sections at the rear of these panels.
Summary of Contents for 427 ROADSTER
Page 4: ...SECTION A PARTS NEEDED 4...
Page 13: ...SECTION A PARTS NEEDED 13...
Page 55: ...55 SECTION C CHASSIS PREPARATION Assembling the chassis and preparation for paint...
Page 56: ...56...
Page 70: ...70 SECTION E BODY PREPARATION...
Page 73: ...SECTION E BODY PREPARATION 73...
Page 76: ...SECTION E BODY PREPARATION 76 ebod stripe...
Page 95: ...95 SECTION F SUSPENSION ASSEMBLY...
Page 107: ...107 SECTION G BODY INTERIOR...
Page 117: ...SECTION G BODY INTERIOR 117 eint tunnel...
Page 142: ...142 SECTION H FINAL OPERATIONS...