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Fiberfab Aztec 7, Assembly Manual

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Fiberfab Aztec 7 Assembly Manual Download Page 28

 
 

Use a brush to apply contact cement to the back of the veneer and faces of the cash and console. Follow 

instructions on the can of cement and apply the veneer to the cash and console. 
 
 

Mark the veneer for holes to be drilled for gauges and switches mounted in the dash and console using the 

templates. Now drill all the holes using the proper size drill bits and hole saws as indicated on the templates. 
 
 

Drill holes in top of the dash for defroster outlets at location shown in Figure 28. Slide the dash pad over the 

dashboard. Push the pad back as tightly as possible and mark the location of the defroster outlets from under the dash. 
Remove the dash pad and cut the holes for the outlets where marked. Replace the pad on the dash and instill defroster 
outlets as shown in Figure 30. 
 
Figure 27 Drill Through Dashboard and Veneer Per Templates 
 
Figure 28 Location of Defroster Vents 
 
Figure 29 Padded Dash Over Dashboard 
 
Figure 30 Defroster Vent Installed In Dashboard 
 

8.  Installation of Gauges and Switches 

 
Tools Required   

Needle Nose Pliers 

 

 

 

Pliers 

 

 

 

Screwdriver 

 

 

 

Socket Set – ¼ inch 

 
Parts Required   

Ff #Z409 Dashboard 

 

 

 

Ff #Z410 Overhead Console 

 

 

 

Ff #X161 Speedometer 

 

 

 

Ff #X162 Tachometer 

 

 

 

Ff #X165 Oil Temperature Gauge 

 

 

 

Ff #X164 Fuel Gauge 

 

 

 

Ff #X163 Ammeter 

 

 

 

Ff #X135 Turn Signal Indicator Lights 

 

 

 

Ff #X135 High Beam Indicator Light 

 

 

 

Ff #X132 Ignition Switch 

 

 

 

Ff #X142 9 Switches 

 

 

 

Ff #Z784 Wiring Harness 

 
Refer to Figure 31 
 
 

Install all gauges and switches in dash and overhead console as shown in Figure 31. Wire dashboard according 

to instructions included with the wiring harness. Do not wire the overhead console. 
 

Summary of Contents for Aztec 7

Page 1: ......

Page 2: ......

Page 3: ...r Pan The Gull Wing Doors Preparing the Gull Wing Doors Cutting the Side Window Openings Preparing the Door for Latches Locating the Door Hinges Mounting the Door Hinges Installing the Door Assist Cyl...

Page 4: ...Supports Wiring the Front of the Car Installing the Brake Fluid Reservoir Installing the Hood Installing Locking Hood Hold down Pins Gas Tank Installation Painting Mirrors and Trim Bolt Descriptions...

Page 5: ...tec 7 kit remember the necessities are the floor pan complete front end transaxle and engine If these parts are complete and not damaged the car is useable Don t be fooled by a bent up rusted body The...

Page 6: ...ront and rear seats 2 Remove the battery save brackets 3 Remove voltage regulator 4 Remove the four bolts from the rear body mounting flange save 5 Remove the bolt from each side under the rear seat b...

Page 7: ...steering box pull the shaft up and forward out of the body 29 Remove the bolts that secure the body to the front torsion tubes beneath the area occupied by the gas tank Save these bolts 30 Raise the...

Page 8: ...th the edge of the floor pan flanges 5 Use a cold steel chisel again to remove the seat rails on both sides of the pan 6 Repair any floor pan damage using fiberglass cloth and resin On small holes use...

Page 9: ...Figure 4a VW Chassis Figure 4b Removing Seat Rail...

Page 10: ...t the brake lines and steering damper at this time if you plan to do your own welding When the procedure is complete the 4 cut portion of the housing with the center bolt should move freely from the r...

Page 11: ...ard out of the spring plate NOTE Spring plates are under tension when they disengage from the rear axle keep hands clear 6 Once the spring plate is disengaged rotate the spring plate one notch counter...

Page 12: ...chassis The illustration below shows both hangers in place on the mounts formerly used to secure the VW body When the tail section is installed shims washers may have to be placed under the front rear...

Page 13: ...cone Refer to Figure 7 Cut two lengths of heater tubing 24 inches long each Apply a bead of silicone all the way around the tube approximately 1 inch from the end as illustrated in Figure 7 Install he...

Page 14: ...and fasten the regulator to the shroud using 10 X1 2 inch sheet metal screws A ground wire of 14 gauge wire should be cut and installed under one of the regulator mounting screws and the other end fas...

Page 15: ...ated at the base of the distributor Install the Fiberfab oil pressure sending unit in the same location The location of the sending unit is shown in Figure 8 Remove the oil dipstick and replace it wil...

Page 16: ...Figure 10 Oil Temperature Sending Unit Figure 11 Air Cleaner...

Page 17: ...13 and 14 1 Cut the openings in the console for the shifter and hand brake lever Use the plate in the shifter kit for the shifter opening pattern Dimensions for the hand brake are shown in Figure 12 2...

Page 18: ...Figure 13 Installing Lower Console Figure 14 Installing Shifter...

Page 19: ...red Ff X187 Speedometer Cable Refer to Figure 15 Push the speedometer cable through the left front spindle and hub dust cover Insert cotter pin through cable end Figure 15A Placement of Speedometer Ca...

Page 20: ...areful to leave the scribe mark on the finished part Then using the 40 grit sandpaper and a sanding block sand all the edges smooth to the scribed mark Figure 16 Windshield Opening 2 Cutting the Rear...

Page 21: ...ning 3 Cutting the Door Openings Tools Required 40 Grit Sandpaper Tape Drill 3 8 inch Drill Bit Jigsaw Refer to Figure 18 Cut the opening on each side of the main body section Sand to the scribed line...

Page 22: ...froster Bolt Kit 2 Refer to Figures 19 and 20 Measure and drill holes as shown in Figure 19 using a 5 16 inch drill bit Install defroster motor on the inside of the car The air outlet ducts should fac...

Page 23: ...Figure 20 Detail Defroster Installation Figure 21 Motor Location Top View...

Page 24: ...to mount the wiper motor as shown in Figure 21 Use the dimple at the center of the windshield opening to locate the vertical line Use a 5 8 inch drill bit to drill the center hole for the wiper motor...

Page 25: ...Harness Tools Required Drill 1 1 2 inch hole saw Refer to Figures 23 and 24 Use a 1 1 2 inch holes saw to drill holes in the firewall and inner liner as shown in Figures 23 and 24 Figure 23 Wiring Har...

Page 26: ...Figure 24 Wiring Harness Drill Hole Location Figure 25 Dashboard and Overhead Console...

Page 27: ...roster Kit Ff Z759J Dash Pad Refer to Figure 25 Through 30 Trim all flanges using 40 grit sandpaper Then sand smooth using 120 grit sandpaper Using medium steel wool rub the entire dash and console un...

Page 28: ...re marked Replace the pad on the dash and instill defroster outlets as shown in Figure 30 Figure 27 Drill Through Dashboard and Veneer Per Templates Figure 28 Location of Defroster Vents Figure 29 Pad...

Page 29: ...Figure 31A Dashboard Layout for Gauges Figure 31B Overhead Console Layout...

Page 30: ...Bolt Kit 4 Ff M5604B Wiring Harness Clamp Refer to Figure 32 Place dash under the windshield opening and drill through the body and dash at the dimples using a 3 16 inch drill bit as shown in Figure...

Page 31: ...front of the main body Allow inch of fiberglass from the edge of the flange to the edge of the bolt holes as shown in Figure 32B Use the plate as a template to scribe mounting holes on the underside o...

Page 32: ...nly spaced holes in the reinforcing pipe with a 3 16 drill bit Using the pop rivets in bolt kit 5 pop rivet six wire harness clamps around the wire bundle to the reinforcing pipe as shown Run the wire...

Page 33: ...Figure 33B Detail Wiring Harness Clamps to Reinforcing Pipe Figure 34 Wiring Harness Routing...

Page 34: ...Figure 35 Fuse Box Installation...

Page 35: ...e about the size of a penny every two feet or so Press the gasket down before the silicone sets Figure 36 Floor Pan Gasket to Chassis Place the man body section on the pan and move rearward as far as...

Page 36: ...Figure 37 Mounting Main Body to Chassis Figure 38 Detail Main Body to Chassis...

Page 37: ...nd rear of the main body section using a 3 16 drill bit Remove the box and run a bead of silicone along the flanges Pop rivet the box in place using bolt kit 10 To install the top of the battery box l...

Page 38: ...Figure 41 Center Console to VW Floor Pan Location of Bolt Holes Figure 42 Position Luggage Box on Main Body...

Page 39: ...Figure 43 Luggage Box Lid and Hinge Attachment Figure 44 Mounting Lid to Main Body...

Page 40: ...Assorted files 40 80 and 120 grit sandpaper Putty Knife Parts Required Body Filler Refer to Figure 45 File and sand the inside of the door edges to about 3 8 thick as shown in figure 45 Fill low spot...

Page 41: ...efer to Figure 45 Drill a 3 8 hole in the area where the side glass will be installed Use the hole for starting the cut with the jigsaw Cut the opening out and sand to the scribe line as shown This wi...

Page 42: ...door latch indent and 4 1 2 down from the top of the door flange Mark the intersection of the measurement and cut 6 inch holes at these points as show in Figure 46 Figure 46 Access Holes for Installi...

Page 43: ...igure 48A Notching Door Latch Inset The inch hole drilled though the outside door skin earlier is for the door lock cylinder A pattern of the lock cylinder should be made and traced around the inch ho...

Page 44: ...Use medium steel wool to sand the door flange and window opening Paint these areas with the flat black paint as shown in Figure 49 Figure 49A Preparing Door and Window Flanges...

Page 45: ...lign the top of the door with the roof of the main body and the lower edges of the door with the body When you are satisfied with the door alignment tape the door in place Measure 3 inches from each o...

Page 46: ...nd the door top Center the hinge pins over the space between the door top and the main body roof Mark the door top and main body roof through the holes in the hinges Mark all four hinge holes and remo...

Page 47: ...with bolts and huts in bolt kit 12 as in Figure 50B Figure 50B Mounting Door Hinges Open and close the doors to be certain they operate freely It may be necessary to sand the outer door flange as sho...

Page 48: ...28 Assist Cylinder Safety Clip Bolt Kits 13 and 14 Refer to Figures 52A B C 53A through E Open the door and locate the assist cylinder bracket on the main body door flange by measuring 3 inches from t...

Page 49: ...53 The center of the single hole should be even with the horizontal line marked on the door panel The dimensions for locating the bracket are shown in the illustration After locating the bracket as de...

Page 50: ...Figure 53A Position Bracket on Doors Figure 53B Detail Mounting Assist Cylinder Brackets to Door Figure 53C Assist Cylinder Bracket Installed...

Page 51: ...Figure 53D Detail Assist Cylinder Ball Stud Figure 53E Detail Ball Stud and Safety Clip...

Page 52: ...e door latch to the latch plate with bolts in bolt kit 15 Bolt the plate to the door being certain the pin from the outside lock cylinder fits in the slot in the latch as shown in Figure 54 Trim off t...

Page 53: ...se the striker as a template to mark for bolt holes and the portion of the door jamb to be removed under the striker plate Drill inch holes cut the door jamb for the striker and bolt the plate to the...

Page 54: ...Parts Required Ff Z755 Rubber Adjustment Stops Bolt Kit 17 Refer to Figure 56 Using the 5 16 inch drill bit drill 4 holes in each door jamb at the points indicated in Figure 56 Install the doorstops...

Page 55: ...he glass on the door ABOVE the window Remove the glass and drill a 5 16 inch hole on the marks as shown in Figure 57 This is where the glass hinge will attach to the door Working from inside the car d...

Page 56: ...e Kit Bolt Kit 18 Refer to Figure 59 and 60 Install all hardware on the side glass as shown in Figure 59 Install the side glass in the window opening using bolt kit 18 You may have to grind the bolt h...

Page 57: ...aw Insert the dimmer switch through the firewall and use the mounting plate of the switch to scribe the two mounting holes onto the firewall Drill using a inch drill bit Again insert the dimmer switch...

Page 58: ...Figure 64 Detail Mounting Dimmer Switch to Fire Wall...

Page 59: ...dliner will meet the raised areas of the inner liner as shown in Figure 66 Do not apply cement to eh very rear edge of the headliner This area must remain accessible for the installation of the tail p...

Page 60: ...Figure 66 Headliner and Contact Cement Figure 67 Contact Cement to Inner Liner...

Page 61: ...s shown in Figure 69 Allow cement to dry and fold that end over about 1 1 2 inches as illustrated This folded edge is installed where the pillar material meets the underside of the dash as in Figure 6...

Page 62: ...Figure 70 Headliner to Windshield Pillar...

Page 63: ...e 1 1 2 inch paintbrush Parts Required Ff MX194 Contact Cement Ff Z759A Rear Firewall Upholstery Refer to Figure 71 Apply cement to rear firewall and upholstery and allow to dry Press the upholstery i...

Page 64: ...9B Front Wall Upholstery Note there are 3 pieces in this group Refer to Figure 72 Paint cement on the front firewall and all three pieces of upholstery and let the cement dry Install the center sectio...

Page 65: ...t brush Parts Required Ff MX194 Contact Cement Ff Z759C Side Panels Refer to Figure 73 Apply cement to fiberglass where side panels will be installed Paint cement on the side panels Allow cement to dr...

Page 66: ...f Z707 Flange Trim Bolt Kit 21 Refer to Figure 74 Measure the doorjamb and cut a length of trim to fit Smooth the edges with a fine file Bend the trim as necessary to fit Drill holes in the fiberglass...

Page 67: ...f MX194 Contact Cement Bolt Kit 22 Refer to Figure 75 Apply contact cement to sides of console and material that covers the side Press material in place after the cement has dried Install the center p...

Page 68: ...arts Required Ff X120 Shifter Boot Refer to Figure 76 Install the shifter boot over the lever Use the cover as a template for drilling 4 1 8 inch holes as shown in Figure 76 Fasten the boot and cover...

Page 69: ...o Figure 77 Cement the floor mats in place using the procedure for cementing upholstery described in previous operations Install the number cover in the same manner Note You may not want to cement the...

Page 70: ...8 79 and 80 Attach the pull strap to the inner panel of the door with 4 screws from bolt kit 23 as in Figure 78 Fasten the S hook to the latch arm as shown and squeeze the hook closed with the pliers...

Page 71: ...Figure 79 Door Pull Strap to Latch Arm Figure 80 Attaching Door Panel...

Page 72: ...ired Ff X181 Heater Vent Parts Refer to Figures 83 and 84 Measure the outside of the rear firewall and cut 2 inch holes as indicated by Figure 83 Install the heater vent outlets as shown in Figure 84...

Page 73: ...Figure 84 Installing Heater Vents and Heater Hose...

Page 74: ...d wiring harness to the overhead console per the instructions with the wiring kit Drill four 3 16 inch holes as shown in Figure 85 Place the console in place and mark the molded plates in the roof thr...

Page 75: ...car on jack stands and remove the left front wheel Thread a piece of string through the inch hole and line it up with the center of the steering box and the center of the hole in the dashboard for the...

Page 76: ...88 Center the steering shaft and the flange and drill two 5 16 inch holes Bolt the assembly together as shown in Figure 89 using bolt kit 26 Install the steel plate to the steering column using the c...

Page 77: ...Figure 89 Steering Column Flange Figure 90 Steering Column Support...

Page 78: ...ed Socket Set Parts Required Horn Wire Ff X157 Adapter Kit Ff X155 Steering Wheel Refer to the Instructions included with the steering column adapter steering wheel kit and Figures 93 and 94 Figure 93...

Page 79: ...14 missing...

Page 80: ...at one side and running the gasket all the way around Trim the end of the gasket off about inch longer than necessary as shown in Figure 97 Make certain the connecting lip of the gasket is on the out...

Page 81: ...o approximately inch from the edge of the windshield opening as shown in Figure 99 Figure 99 Headliner Over Windshield Opening Flange Mask the edge of the windshield inside to allow approximately 1 in...

Page 82: ...re the silicone sets Figure 101 Windshield Installation Body Preparation With the aid of an assistant lift the windshield into place and position it evenly on the windshield flange as shown in Figure...

Page 83: ...Figure 103 Detail Smooth Silicone Along Edge of Windshield...

Page 84: ...rs Ff MX194 Contact Cement Bolt Kit 27 Bolt Kit 28 Refer to Figures 104 through 110 Sand all seat edges smooth and round with 40 grit sandpaper Mark and drill four 5 16 inch holes at points indicated...

Page 85: ...lt the bracket to each end of the seat rail through the top hole in the bracket Use bolt kit 27 The L of the bracket should face the center of the seat Apply contact cement to the rear of the seat bac...

Page 86: ...Figure 107 Seat Back Upholstery Figure 108 Installing Seat Covers...

Page 87: ...on of the brackets on the carpet for reference this can be done with a piece of masking tape and find the seat location best suited to you by adjusting the seat as desired Once you find the proper sea...

Page 88: ...Figure 110 Detail Seat Bracket to Chassis...

Page 89: ...Kit 29 Bolt Kit 30 Refer to Figures 111 through 118 To cut the louver holes open drill a inch hole about 1 6 inch away from the scribe line Use a carbide router bit to cut the holes open along the scr...

Page 90: ...panel will meet the inner panels at right angles on each side of the car The inner panels must have a 3 inch notch cut in them as shown in Figure 113 to allow for the fittings of the light assembly F...

Page 91: ...lace the taillight units in the holes and put the mounting brackets over the bolts in the light units Secure the taillights in place with bolt kit 29 and in Figure 114 Figure 114 Installing Taillights...

Page 92: ......

Page 93: ...he center mark and scribe the outline for the lights and cut the hole open Mark the location of the mounting studs on the tail section and drill them with a 1 8 inch drill bit Bolt the light in place...

Page 94: ...o lines inch and 5 inches from the bottom edge of the rear panel Mark four points along each line near the 3 inch access holes as shown in Figure 118 Drill the marked points with a inch drill bit Thes...

Page 95: ...t Kit 31 and 32 Ff Z758 Two License Plate Lights Two Steel Washers Refer to Figures 119 to 122 Sand the bumper flanges smooth with 120 grit sandpaper Mark and drill the holes for the license plate lig...

Page 96: ...an assistant hold the bumper in place as shown in Figure 121 From inside the car drill through the eight bumper mounting holes into the bumper flanges with inch drill bit Reaching through the 3 inch...

Page 97: ...h 128 Run the wiring for the engine along the tail section supports and fasten to the supports using the wire ties in the wiring kit as shown in Figure 123 Wire the engine according to the directions...

Page 98: ...Mark the center of the slotted holes in the pivot bracket on the inner panel Drill these marks with a 3 8 inch drill bit Bolt the brackets to the liner using bolts left in bolt kit 1 as shown in Figu...

Page 99: ...n to the open position and enlarge the inch hole just drilled to inch Bolt the anti sway bumper in place with bolt kit 33 as shown in Figure 127 Drill the matching inch in the main body flange to 1 5...

Page 100: ...section and drill the marks with a inch drill bit Enlarge the hole to accept the hold down pins by drilling the inch hole with a 5 8 inch drill bit Do the same with the inch holes just drilled in the...

Page 101: ...Figure 130 Installing the Holding Pins Figure 131 Installing Holding Pins Chrome Plate...

Page 102: ...e 133 Turn the adjusters up or down until the roof of the main body and the tail section are in alignment The adjusters nearest the hold down pins should be set so slight pressure is required to line...

Page 103: ...Light Sockets Ff Z775 Turn Signal Sockets Ff Z776 Backup Light Sockets Refer to Figure 134 Install the rear edge of the headliner that was left loose when interior was installed Figure 134 shows the l...

Page 104: ...folded over the fiberglass edge allowing about 3 16 inch to remain on the edge as shown in Figure 135 Apply a think film of trim adhesive to the fiberglass and the weather stripping as illustrated in...

Page 105: ...Figure 137 Weather stripping Installed...

Page 106: ...the openings for the headlights along the scribed lines and sand the edges smooth Figure 138 shows the openings to be cut in the nose section Refer to Figure 139 and cut out the gas tank opening at th...

Page 107: ...Figure 139 Gas Tank Opening Nose Section Figure 140 Location of Side Marker Lights...

Page 108: ...0 Refer to Figures 141 through 149 Cut round holes in the headlight boxes on the scribe marks and shown in Figure 141 Trim the back of the headlight boxes on the scribed lines and drill 5 16 inch hole...

Page 109: ...Figure 142 Headlight Pivot Holes Figure 143 Preparation of the Headlight Bezels...

Page 110: ...ose and the headlight openings mark the pivot holes on the inner liner Remove the doors and drill the marks with a 5 16 inch drill bit as shown in figure 144 Figure 144 Positioning Headlight Box in No...

Page 111: ...Figure 145A Positioning Headlight Stops Figure 145B Attaching Headlight Stop...

Page 112: ...the location shown in Figure 146 Drill the holes through the pivot and light box with a inch drill bit and install the pivots using bolt kit 38 Figure 146A Headlight Pivot Bracket Figure 146B Detail H...

Page 113: ...the adjusters Drill 3 16 inch holes and bolt the adjusters down using bolt kit 39 as shown in Figure 147 Make certain the low beams are to the outside of the car Notch the headlight bezels for access...

Page 114: ...adlight bezels of the light boxes and drill a 1 16 inch hole through the box using the holes in the bezel as guides Assemble the bezel to the box as shown in Figure 149 using the screws in bolt kit 40...

Page 115: ...to Figures 150 Through 157 Install the headlight assembly into the headlight holes in the nose section Making sure the stops are clear Tape the assembly in the opening and stand the nose section on e...

Page 116: ...the outer lift arm making sure both arms are flat Drill a 5 16 inch hole through the lift arm and shaft Bolt the arm to the shaft using bolt kit 42 Figure 152 shows the assembly sequence of the lift m...

Page 117: ...Assembly Refer to Figure 154 and bolt pivot arms to pivots on the headlight boxes using bolt kit 43 Make sure the arms work freely before tightening the jam nuts Figure 154A Pivot Arm Installation Fi...

Page 118: ...e motor Positioning the headlights in closed position run motor around so arm is in the same position in shown in Figure 155D and install micro switch on the steel bracket as shown in Figure 155B The...

Page 119: ...Figure 155B Position for Motor Assembly...

Page 120: ...Figure 155C Arm Position Headlights Open Figure 155D Arm Position Headlights Closed...

Page 121: ...ening jam nuts Use bolt kit 44 for this operation Figure 156A Motor Bracket to Inner Panel Figure 156B Lift Arm to Pivot Arm Drill through the activator lift arm and the lift mechanism shaft with a 5...

Page 122: ...to Figures 158 through 163 Sand all the edges of the bumper smooth with the 40 grit sandpaper Cut the holes as shown in Figure 158 at the pre scribed lines Figure 158 Preparation of the Front Bumper...

Page 123: ...llow the silicone to set before proceeding Draw a line around the nose section about 1 1 4 inch from the flange Drill inch holes as shown in Figure 161 Keep the holes near the access holes in the nose...

Page 124: ...Figure 162 Bumper Mounting Bolt Holes Figure 163 Mounting Front Bumper to Nose...

Page 125: ...ill bit as shown in Figure 164 Drill completely through the back wall of the nose and the firewall of the main body When drilling in this area be careful not to drill into the wiring harness Use bolt...

Page 126: ...Figure 165 Nose to Main Body Figure 166 Attaching Nose to Main Body Side Flanges...

Page 127: ...rsion bar tube Bolt loosely in place with the U bolts in bolt kit 47 Slide the support bar against the inner panel in the nose section as shown in Figure 168 Angle the support bars upward to allow for...

Page 128: ...Figure 169A Front Support to Torsion Bar Tube Figure 169B Front Support to Inner Panel...

Page 129: ...48 Wire Harness Clamps Refer to Figures 170 and 171 Install horn and horn relay on inner panel as shown in Figure 170 Route the wiring harness as shown in Figure 171 Wire harness claps are installed...

Page 130: ...72 shows how this is done Fasten in place with bolt kit 49 Directly below the reservoir drill the holes necessary to connect the master cylinder and the reservoir Unplug the lines at the top of the ma...

Page 131: ...lt Kit 50 Hood Hinge Hood Rod Refer to Figures 174 through 177 Sand all flanges of the hood smooth using the 40 grit sandpaper Mark the point shown by the measurements in Figure 174 on each side of th...

Page 132: ...ld in place using the holes just drilled in the hood opening flange as a guide Perform this operation on each side of the hood Install the rod in the holes in the hood Slide the rod into one of the 5...

Page 133: ...Figure 176 Positioning Hood Support Rod Figure 177 Support Rod Fastened to Hood...

Page 134: ...Figure 178 Locating Locking Hood Hold down Bracket Figure 180 Locking Hold down pins...

Page 135: ...ill the marks with a 5 16 inch drill bit Bolt the clips in place with bolt kit 52 as shown in Figure 181 NOTE Depending on the year of VW tank used if may be necessary to shorten and or reposition the...

Page 136: ...n areas such as headlight boxes body flanges louver edges etc Fill any scratches holes or uneven edges in the fiberglass using a glazing body putty Re sand using the 320 grit sandpaper If putty was us...

Page 137: ...mirror from the bracket by removing the hinge screw Use the bolt holes in the bracket to scribe bolt holes onto the body Drill Reassemble the mirror and mounting bracket Secure the mirror to the body...

Page 138: ...Wire Harness to Pipe 6 2 3 16 X 5 8 Pop Rivets Fuse Box 7 24 24 24 24 5 16 18 X 1 1 2 HHCS 5 16 18 Nut 5 16 Fender Washer 5 16 Washer Main Body to Pan 8 2 2 4 20 X 1 1 2 HHCS 20 Nut Washer Tunnel Cons...

Page 139: ...18 X HHCS Seat Rails and Seat 28 8 8 8 5 16 18 X 1 1 2 HHCS 5 16 18 Nut 5 16 Washer Seat To Pan 29 4 4 20 Nut Washer Taillight Bracket 30 4 4 4 8 32 X 1 FHPHMS 8 32 Nut 8 Washer Side Marker Light Rea...

Page 140: ...ets Hone Switch 45 8 8 16 20 X 1 1 2 HHCS 20 Nut Washer Front Bumper 46 14 14 28 5 16 18 X 1 1 2 HHCS 5 16 18 Nut 5 16 Fender Washer Nose to Main Body 47 2 4 4 5 16 2 1 4 Muffler Clamps 5 16 18 X 2 1...

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