SUPPLEMENTARY INSTRUCTIONS ROLLUP

SUPPLEMENTARY INSTRUCTIONS
FOR INSTALLING
ROLLUP, CURVED-GLASS SIDE-WINDOWS
IN THE FIBERFAB
VALKY3IE KIT
A~
ff J
1GER
5
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Page 43 o f t h e V a l k y r i e K i t mounting i n s t r u c t i o n s
r e f e r s t o t h e i n s t a l l a t i o n of Ford LTD c u r v e d - g l a s s , r o l l - q p
The f o l l o w i n g s u p p l e m e n t a r y i n s t r u c t i o n s C o m p l e t e
windows,
t h e d e t a i l s o f t h i s i n s t a l l a t i o n and f o l l o w t h e t e c h n i q u e s
we have found most p r a c t i c a l and l e a s t e x p e n s i v e i n t h e
c o n s t r u c t i o n o f o u r f a c t o r y - b u i l t VaLkyries.
The V a l k y r i e side-window o p e n i n g s are designed t o
a c c e p t Ford Mustang (e.g., 1965 h a r d t o p ) v e n t windows and
Ford LTD (e.g., 1966 4-door h a r d t o p ) c u r v e d - g l a s s s i d e
The d o o r i n n e r - pane 1s a r e d e s i g n e d t o acCOmodate
windows.
t h e above mentioned windows and t o s u p p o r t a r o l l - u p
mechanism--s l i g h t ly-modif i e d VW-Karman- Ghia ( s e e PARTS LIs T
and t e x t below f o r i d e n t i f i c a t i o n and p a r t s numbers)--for
r a i s i n g and l o w e r i n g t h e s i d e windows w i t h a s t a n d a r d c r a n k ,
F i g u r e 1 shows t h e V a l k y r i e d o o r inner p a n e l ( i n t h i s
photo a right d o o r p a n e l i s shown) w i t h the hardware mounting
h o l e s l a b e l l e d - - t h e p o s i t i o n s of t h e s e h o l e s are cast i n t o
t h e p a n e l s as "dimples1f i n t h e f i b e r g l a s s s u r f a c e . R e f e r r i n g
t o t h e f i g u r e - - t h e t w o " A w h o l e s are used t o mount t h e
The six "BW h o l e s are used t o mount
r o l l - u p guide-track.
The "Cn h o l e s ( t h e r e
t h e r e g u l a t o r (crank-up mechanism),
a r e f o u r ) are d r i l l e d u s i n g t h e v e n t window frame as a
guide ( s e e subsequent f i g u r e s ) .
A l l h o l e s a r e d r i l l e d with
a 5 / 1 6 ~d r i l l b i t ,
F i g u r e 2 shows a s t o c k ( r i g h t ) and modified r o l l - u p
g u i d e - t r a c k and t r a c k - r i d e r ( t h e VW p a r t s numbers are:
1 4 1 - 8 3 7 - 5 5 2 ~ f o r a r i g h t door and 141-837-551B f o r a l e f t
door),
The f i r s t s t e p i n modifying t h e g u i d e t r a c k i s t o
Cut t h e t o p ( t h e t r a c k r i d e r s a r e n e a r e s t the t t t o p s w of the
g u i d e - t r a c k s i n Fig. 2 ) of t h e t r a c k a t a 25-degree angle
as shown i n t h e f i g u r e , h e n make a p a r a l l e l c u t 18" along
t h e t r a c k . The e x t r a s l o t i n t h e t r a c k - r i d e r i s added
subsequently.
F i g u r e 3 shows t h e r e v e r s e s i d e of t h e g u i d e - t r a c k s ,
Note t h a t t h e bottom a t t a c h m e n t - p o i n t must be moved u p
4 3/8fl.
To perform t h i s r e p o s i t i o n i n g d r i l l o u t t h e
a t t a c h i n g s p o t welds ( o b v i o u s l y , t h i s o p e r a t i o n must be
performed b e f o r e t h e t r a c k i s s h o r t e n e d t o 18"), remove
the a t t a c h m e n t p o i n t and s e c u r e i t i n i t s new p o s i t i o n - w e l d i n g ( a s i n t h e f i g u r e ) o r epoxy cement are a p p r o p r i a t e
f o r t h e f a s t e n i n g - - s c r e w s o r r i v e t s should n o t be used
b e c a u s e n o t h i n g s h o u l d p r o j e c t on t h e o t h e r s i d e of t h e track,
FIGURE 1
FIGURE 3
FIGURE 2
sv-2
Figure 4 shows a s t o c k ( r i g h t ) and modified r e g u l a t o r
( t h e VW p a r t s numbers a r e : 141-837-502A f o r a r i g h t door
and 1 4 1 - 8 3 7 - 5 0 1 ~f o r a l e f t d o o r ) , To modify t h e r e g u l a t o r
t h e Lshaped arm must be r o t a t e d 32-degrees clockvise as
viewed i n Figure 4 . To move t h e a r m , d r i l l o u t t h e lower
( i n t h e f i g u r e ) s e c u r i n g r i v e t and move t h e arm so t h a t t h e
r i v e t h o l e i s p o s i t i o n e d 2" away from i t s o r i g i n a l position-s e c u r e by welding o r epoxy, Note a l s o t h a t t h e nup-travel
s t o p f t must be lengthened t o 2 5 / 8 " .
FIGURE 4
Figure 5 shows t h e LTD window g l a s s i n s t a l l e d i n a
Vd g l a s s - h o l d e r ( p a r t number 141-837-571~) using b u t y l
t a p e ( s i l i c o n rubber seal may a l s o be u t i l i z e d - - s e e your
l o c a l p a r t s s t o r e f o r o t h e r window-af f i x i n g materials 1.
The t r a c k - r i d e r i s a t t a c h e d t o t h e glass-holder ao t h a t
t h e r i d e r is p a r a l l e l w i t h t h e f r o n t edge of t h e glass a s
Use one o r i g i n a l s l o t t e d h o l e and c u t
shown i n the f i g u r e .
a second a8 i n Figures 3, 4 and 5,
FIGURE 5
sv- 3
Figure 6 shows t h e r o l l - u p g u i d e - t r a c k and v e n t window
assembly mounted on t h e inner-panel.
Before mounting the
vent window c u t - o f f t h e window guide channel j u s t below
t h e lower a t t a c h i n g p l a t e as i n t h e f i g u r e , Also use
Figure 7 as a f u l l - s i z e t e m p l a t e t o re-contour t h e t o p of
t h e vent window frame t o match contours of t h e Valkyrie
window opening, Use a f i l e o r g r i n d e r t o c a r e f u l l
R e f e r r i n g a g d g u r e 6.remove m e t a l from t h e frame.
a f t e r t h e guide t r a c k and v e n t window a r e l o o s e l y bolted
i n place u s e a square t o s e t t h e t r a c k and t h e channel
p a r a l l e 1.
F i n a l l y , i n s t a l l t h e g l a s s by b o l t i n g t h e g l a s s holder
t o t h e t r a c k - r i d e r - - p o s i t i o n t h e f r o n t edge of the g l a s s
f i r m l y i n t h e guide channel u s i n g t h e s l o t t e d adjustment
Now i n s t a l l t h e r e g u l a t o r by
holes i n t h e track-rider.
engaging t h e L-shaped arm i n the t r a c k - r i d e r and securing
t h e crank assembly to t h e inner panel using s i x b o l t s (get
t h e m e t r i c hardware you need at: your VW d e a l e r ' s p a r t s
The completed r o l l - u p window assembly i s
department),
Be s u r e
shown i n Figure 8 i n t h e maximum "UPn p o s i t i o n ,
t o g r e a s e t h e t r a c k , crank-gear, e t c , b e f o r e i n s t a l l i n g t h e
i n n e r - p a n e l , with mechanism a t t a c h e d , i n t h e door--fasten
t h e panel t o t h e door w i t h f l a t - h e a d b o l t s a t t h e t o p of
t h e door, when n u t s can be a p p l i e d , and w i t h #8 x 3 / 4 "
i n t e r i o r trim screws (with countersunk washers) along
t h e s i d e s and bottom of t h e door, Rote a l s o , i n Figure 8 ,
t h e a p p l i c a t i o n of weather s t r i p p i n g along t h e i n s i d e , top
edge of t h e i n n e r - p a n e l - ~ u s e s m a l l wood screws o r epoxy
cement.
-.-2.P
.
.L
FIGURE 6
FIGURE 8
I
I
'
I
I
I
1
@
TRIm TO BODY CONTOL
@
BOT'TO. nSTOPw
a
PARTS USED:
I
-
FIRERFAU DOWPANELS
1 9 6 5 mUSTANC WINDWIffi
COflPLcfE
1 9 6 5 F W D LTD FRONT DOW WINDOW GLASS
1960 OR - LATER
KARmANN CHIA WINDOW
- - ..- ---. .-
TRIPI C U I D f ASSEMBLI
RELOCATE BClfTDm MOL
@
-
REPIOVE REAR R I V E T [
A N 0 SWING ARM UP 2
( ~ ~ A S U RFRLm
E
CENTE
RIVET HOLE)
@
TRIPI TO BRACKET
-.
RECOMMENDED PARTS LIST
DOOR /WINDOW HARDWARE
Vent Window Assembly
Ford
Side Windov Glass
Window Guide- P a c k
Ford
W/Ghia
Regulator
VW/[hia
Glass-Holder
A r m Rest Base
VW/Ghia
A r m R e s t Pad
Weatherstripping
Ford
Ford
Ford
Door Luck Cylinder
Door Latches
Ford
Ford
S t r i k e r Studs
Ford
Hinges
FtH TOP
RH Bottom
LH Top
, LH Bottom
1965 Hardtop Mustang Vent
Window
1965 4-Door Hardtop LTD
141-837-5520
141-837-551~
141-837-502~
141-83 7 - 5 0 1 ~
141-837-57U
C5ZZ- 6 5 2 4 1 4 L ~
C5ZZ-6524100-AFA
C5ZZ-6551222- B
C5U-6551222-C
C5ZZ-655 13467-A
CSZZ- 655 13466- B
C502-622 1984-A1
C4SZ-632 1813-C
C4SZ- 632 1812-C
C20L6220008
CZOL6220009
Ford
C5AZ-6222810-C.
C5AZ-6222811-B
C5AZ-6222811-C
C5AZ-6222801-B
.
VALKYRIE KIT
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Division of Velocidad, I n c .
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1/
GENERAL
2/
CONSTRUCTION m A T E R I A L S
3/
ACQUIRING COmPONENTS
a.
C o r v a i r f r o n t s u s p e n s i o n end s t e e r i n g a s s s m b l y
b.
Corvair transaxle
c.
V-8 e n g i n e and b e l l h o u s i n g
d.
Other m a j o r m e c h a n i c a l components
4/
ASSEITBLING THE ENGINE/TRANSAXLE
5/
I N S T A L L I N G THE FRONT SUSPENSION
6/
I N S T A L L I N G THE ENGINE/TRANSAXLE/REAR
7/
COmPLETING THE C H A S S I S PREPARATION
a.
Hydraulic system
~ u e sl y s t e m v
b.
c.
Shift linkage
d.
Cooling system
8/
DlOUNTING THE BODY
9/
PlOUNTING E L E C T R I C A L COmPONENTS
INTRODUCTION
UNIT
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SUSPENSION
WIRING
10/ I N S T A L L I N G WINDOWS AND DOORS
11/ F I N I S H I N G THE I N T E R I O R
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UPHOLSTERY
1 2 / F I N I S H I N G THE EXTERIOR
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PAINTING
PARTS L I S T
OPTIONS L I S T
1/
I N T R O D U C T I O N TO THE VALKYRIE K I T
F i b e r f a b f i r s t i n t r o d u c e d t h e V a l k y r i e concept t o t h e publ i c i n t h e f a l l o f 1966 i n t h e form o f t h e VALKYRIE 500 GT a u t o
mobile,
The 500 GT i s a c o m p l e t e l y f i n i s h e d v e h i c l e i n c o r p o r a t
i n g a c e n t r a l l y - l o c a t e d , 500 hor8epoaer engine, a f i v e speed Zf o u r - w h e e l independent suapension and d i s c brakes,
transaxle,
"topped o f f n w i t h a posh, a l l - l e a t h e r i n t e r i o r and a sleek, u l t
contemporary GT body.
The 500 GT i s undoubtedly t h e f a s t e e t pr
d u c t i o n a u t o m o b i l e ever made a v a i l a b l e t o t h e g e n e r a l p u b l i c
i t i s a l s o one of t h e most b e a u t i f u l ,
The p r i c e o f t h e GT 500
i s $12,500.
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$12,500 f a r a c a r such as t h e 500 GT cannot be c e n s i d e r e d
unreasonable, e s p e c i a l l y when a comparison i s made between t h i a
p r i c e and t h e p r i c e s o f s i m i l a r v e h i c l e s (eg.,
t h e FORD GT-40
a t $17,700, etc.).
Regardless o f t h e r a t i ~ n a l ef o r t h i n p r i c e ,
i t remains, however, beyond t h e budgsts o f a l l b u t t h e most a v i
car buffs.
I t i s r e a l i z e d , b y F i b e r f a b ' s t e c h n i c a l a t a f f , t h a t much c
t h e c o s t o f t h e V a l k y r i e 500 r e s i d e s i n l a b o r e x p e n d i t u r e a and
t h e c o s t a of t h e s p e c i a l l y - p r e p a r e d engine and gearbox
elimi
a t e these h i g h - c o s t i t e m s a t . t h e p r i c e o f t h e V a l k y r i e i s n i g r
i f i c a n t l y reducmd.
The l o w p r i c e o f t h e VALKYRIE K I T
$1495
i m a c c o r p l i s h e d i n t h i s manner, i e . , by t r a d i n g F i b s r f a b ' s psrs
n a l and overhead charges f a r your t i m e and by making p r o v i s i o n g
i n t h e k i t deaign f o r t h e use o f s t a n d a r d a u t o m o t i v e components
s u p p l i e d b y you.
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Whereaa t h e 500 GT i s a completed; and as a r e s u l t expenai
machine, t h e VALKYRIE K I T i s completed by you a t t h e expense of
your t i m e and f o r t h e c o s t of t h e k i t and etandard, r e a d i l y av;
a b l e engine, running-gear and suspension components.
I n partic
l a r , t h e VALKYRIE K I T i n c l u d e s t h e f o l l o w i n g :
I.
S p e c i a l r e c t a n g u l a r - t u b e frame ( 5 " x 2 " x .083n,
3" x 1-1/2" x .083" and 2 " x 2" x .083" s t e e l t u t
i n g w i t h 1/8" s t e e l - p l a t e gusset r e i n f o r c e m e n t s ) ,
2.
The VALKYRIE body complete w i t h console dash, i n .
t e g r a l f l o o r p a n w i t h molded-in seats, and wheelw e l l inner-panels.
3.
Windshield and rear-window glass.
4.
S p e c i a l adapter components which a l l o w you t o ut i l i z e t h e C h e v r o l e t 283/327 c u b i c - i n c h engine*
and C h e v r o l e t C o r v a i r t r a n s a x l e a and r e a r suapen
s i o n ( p o s t 1964) and C o r v a i r f r o n t suspensions.
289 C I D engines may be used i n s p e c i a l order k i t s .
+ Ford
1/
INTRODUCTION TO THE V A L K Y R I E K I T
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CONTINUED
Hence, y o u p r o v i d e o n l y y o u r t i m e and c r e a t i v i t y and a b o u t
$450 ( a v e r a g e ) of m a j o r a u t o m o t i v e s u s p e n s i o n and power compone
i n excess o f t h e purchase p r i c e o f t h e V a l k y r i e K i t ,
F i g u r e 1 shows an o v e r a l l v i e u o f a l l t h e components i n t h
V a l k y r i e k i t and F i g u r e 2 s h o r s , i n d e t a i l , j u s t t h e components
o f t h e C o r v a i r - t o - V 8 a d a p t e r k i t w h i c h comes w i t h t h e V a l k y r i e ,
( I t i s i n t e r e s t i n g t o n o t e i n F i g u r e 2, t h e d i f f e r e n c e s i n l e n c
and d i a m e t e r between t h e C o r v a i r s t a n d a r d t r a n s m i s s i o n i n p u t a t
2Sn l o n g and t h e s p e c i a l F i b e r f a b s h a f t shown. By e l i m i n a t i n g
need f o r t h e l o n g , f l e x i b l e s t a n d a r d s h a f t , F i b e r f a b l s a d a p t a t i
of t h e C o r v a i r t r a n s a x l e is c a p a b l e of h a n d l i n g s i g n i f i c a n t l y a
torque than t h e o r i g i n a l Corvair configuration,-from 265 l b - f
maximum f o r s t a n d a r d C o r v a i r up t o 375 l b - f t f o r t h e F i b e r f a b
V a l k y r i e set-up),
FIGURE 1
FIGURE 2
The t y p i c a l i n v e n t o r y o f t o o l s f o u n d i n m o s t home workshops w i l l p r o b a b l y a u f f i c e t o c o m p l e t e y o u r V a l k y r i e K i t .
A f o r e m o s t c r i t e r i o n i n a l l F i b e r f a b d e s i g n s i s t h a t assembly
p r o c e d u r e s s h o u l d n o t be barseTl on t h e u s e o f any " e x o t i c n c u t t i n g , f a s t e n i n g , e K methods n o t r e a d 1 1 a v a i l a b l e t o t h e
home, 18hobby-typef1 b u i l d e r .
There a r e
ose i n s t a n c e s , of
m i g h t be p r e f e r r e d t o
course, when f o r example, ar.&elding
bolting
i n n o i n s t a n c e , however, i s an e x o t i c t e c h n i q u e
r e q u i r e d n o r w i l l t h e use o f a home workshop a l t e r n a t i v e comp r o m i s e t h e i n t e - g r i t y of y o u r f i n i s h e d V a l k y r i e .
--d
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The f o l l o w i n g t a b u l a t i o n of t o o l s and m a t e r i a l s i s based
on F i b e r f a b ' s f a c t o r y assembly p r o c e d u r e s and e x p e r i e n c e .
I t e m s c o n s i d e r e d essential a r e l i s t e d a p a r t f r o m t h o s e i t e m s
t h a t a r e s i m p l y he
o r t i m e - s a v i n g ( b u t whose f u n c t i o n
he e s s e n t i a l items).
c a n be d u p l i c a t e *
HAND TOOLS
E s s e n t i a l
- 9/16",
d r i v e s o c k e t s : 5/16", 3/811, 7/1611, 1 / Z W ,
5/8",
11/16", 3/411
3/811 - d r i v e r a t c h e t - h a n d l e
C o m b i n a t i o n wrenches (open-end and box-end com3/8"
1 / Z U , 9/16". S/Bn
b i n e d ) : 3/811, 7/16",
S t a n d a r d s c r e w d r i v e r : medium b l a d e
P h i l l i p s s c r e w d r i v e r : medium b l a d e
Straight-edge
1/411,
D r i l l s ( h i g h - s p e e d s t e e l ) : 1/811, 3/16",
5/16", 3/811, 7/16",
l/Zn
F i l e s : 1/41! d i a m e t e r r o u n d - f i l e , f l a t wood r a s p
5/1611 -18
Taps: 1/4"-20,
f l i s c : hacksaw, c e n t e r - p u n c h , k n i f e , hammer,
putty-knife
-
d r i v e e x t e n s i o n s : 3 " and 611
llPop-rivetll
gun
home workshop v a r i e t y (S4.95)
72" s t e e l r u l e
E l e c t r i c a l t e r m i n a l c r i m p i n g t o o l and w i r e stripper
home workshop v a r i e t y ($2.98)
S e t o f wood-working ( h i g h - s p e e d s t e e l n o t r e q u i r e d )
l l 1 , Zn,
3"
h o l e saws, eg., l / Z n ,
Diagonal-cutting-pliers
nChannel-lockn p l i e r s
Jack s t a n d s
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POWER TOOLS
tssential
Electric d r i l l :
W
1/411 c a ~ a c i t v
t r i c d r i l l : 1/211 c a p a c i t y
Sabre saw
Rotary sander/grinder
Hvdrn111i e f 1 nnc, l a c k
2/
CONSTRUCTION PlATERlALS
-
CONTINUED
CONSTRUCTION IIATERIALS
Essential
A s s o r t e d m a c h i n e b o l t s and n u t s : 1/4". . 5/16".
.
3/8", 7/16"
A s s o r t e d r a s h e r s and l o c k i n g - r a s h e r s
Sandpaper: a s s o r t e d c o a r s e and f i n e g r i t s
#16 AWG m i r e : 300 P e e t
#10 AWG w i r e : 50 Peet
S i l i c o n e s e a l : common t y p e s a r e Rubber S e a l a n t
b y t h e flacklenburg-Duncan Company o f Oklahoma C i t y , Dom-Corning DC 750 s e a l a n t ,
General E l e c t r i c sealant, e t c .
Paint, primer, thinner
wy
adhesive k i t
Epoxy p u t t y / f i l l e r
Crimp-on w i r e t e r m i n a l s : r i n g - t e r m i n a l s and
press-on female t e r m i n a l s
A s s o r t e d - l e n g t h "popw r i v e t s and b a c k i n g washers
Acetone
3.
A C Q U I R I N G CONPONENTS
T h i s s e c t i o n i s p r i m a r i l y an a n n o t a t e d p a r t s l i s t o f
ma o r m e c h a n i c a l components r e q u i r e d t o c o m p l e t e y o u r V a l k y r i e
Ed- G e n e r a l l y t h e r e a r e t w o s o u r c e s f o r each i t e m , v i z . , a
C h e v r o l e t ( o r i n some cases, F o r d ) p a r t s d e p o t o r a u t o wreckt h e l a t t e r r e p r e s e n t s t h e most e c o n o m i c a l s o u r c e ,
i n g yards
by f a r .
Arrangements can u s u a l l y be made w i t h r e p u t a b l e a u t o
wreckers t o s u p p l y a npackage-dealn i n c l u d i n g a l l t h e p a r t s
you r e q u i r e a l o n g w i t h some form o f g u a r a n t e e o f t h e i r u s a b l e
condition.
--
--
--
I n the locale o f Fiberfab
t h e San F r a n c i s c o Bay Area
r e p u t a b l e autonobSle dismantlers a r e l i s t e d i n a p u b l i c a t i o n
c a l l e d t h e PARTS LOCATOR.
The PARTS LOCATOR i s i s s u e d m o n t h l y
and c o n t a i n s e x t e n s i v e l i s t s o f a l l t h e wrecked a u t o m o b i l e s
i n yards throughout Northern C a l i f o r n i a .
most l i k e l y , s i m i l a r
p u b l i c a t i o n s e x i s t i n y o u r a r e a and w o u l d a s s i s t you s i g n i f l c a n t l y i f you choose t o u t i l i z e used p a r t s .
For your referencc
t h e PARTS LOCATOR a d d r e s s i s :
PARTS LOCATOR
1696 Washington Avenue
San Leandro, C a l i f o r n i a 94577
The m a j o r components o f i n t e r e s t a r e :
1. C o r v a i r t r a n s a x l e / r e a r s u s p e n s i o n
2.
V-8 e n g i n e
3.
Corvair f r o n t suspension
An e x a c t d e s c r i p t i o n o f t h e s e component g r o u p s i s g i v e n below.
C O R V A I R TRANSAXLE/REAR SUSPENSION
T h i s component group, aa used i n t h e V a l k y r i e , is composed o f :
1. The d i f f e r e n t i a l / r i n g and p i n i o n h o u s i n g
2.
The gearbox
3.
Two a x l e s ( f o u r u n i v e r s a l - j o i n t s )
4.
Two f o r g e d - s t e e l s u s p e n s i o n l i n k s
5.
Two s t a m p e d - s t e e l s u s p e n s i o n l i n k hangers
6.
T r o shock a b s o r b e r s
7.
Two s t a m p e d - s t e e l r a d i u s - a r a / b e a r i n g c a r r i
hub a s s e m b l i e s
8.
Two wheel/brake a s s e m b l i e s
9.
Two c o i l s p r i n g s
These components ( a s p i c t u r e d i n F i g u r e 3) c o m p r i s e t h e
less bell
t o t a l 1965 C o r v a i r t r a n s a x l e / r e a r s u s p e n s i o n u n i t
h o u s i n g and e n g i n e c r a d l e s .
The 1966-67 u n i t s a r e i d e n t i c a l
w i t h t h e e x c e p t i o n t h a t t h e gearbox i s b i g g e r (1-5/61 l o n g e r )
and c o n t a i n s " b e e f i e r " g e a r s .
(WHENA VALKYRIE K I T ORDER I S
PLACED THE YEAR OF THE C O R V A I R GEARBOX TO BE USED mUST BE
SPECIFIED).
--
--
3.
ACQUIRING COMPONENTS
-
CONTINUED
1965 C o r v a i r Rear Suspension/Transaxle Unit
i
.
,
, -;.'
1-4
C O R V A I R FRONT SUSPENSION/STEERING
ASSEm8LY
The C o r v a i r
1960 t o p r e s e n t
f r o n t suspension/steeri n g assembly c a n be removed f r o m t h e C o r v a i r c h a s s i s as a comp l e t e u n i t s i m p l y b y l o o s e n i n g and r e m o v i n g a b o u t a dozen b o l t s .
The b a s i c f r o n t s u s p e n s i o n cross-member i s shown i n F i g u r e 4
n ~ t et h a t j u s t f o u r b o l t s r e t a i n t h i s e n t i r e u n i t .
To t h i s
basic s t r u c t u r e are attached,
--
--
--
1.
2.
3.
4.
5.
6.
7.
8.
9.
R i g h t and l e f t upper "Alarmsn
R i g h t and l e f t l o w e r s u s p e n s i o n l i n k s
( i t e m s 1 and 2 a r e stamped e t e e l p a r t s )
Two s p r i n g s
Two s h o c k - a b s o r b e r s
Two f o r g e d t r a i l i n g arms
R i g h t and l e f t s p i n d l e s
R i g h t and l e f t hubs and b e a r i n g s
R i g h t and l e f t b a c k i n g - p l a t e s and b r a k e s
R i g h t and l e f t b r a k e drums
Up t o and i n c l u d i n g 1964 t h e hubs and wheels have a f o u r In
b o l t bolt-pattern.
1965 t h e p a t t e r n was
changed t o f i v e - b o l t
( f r o n t and r e a r ) .
The
1960, ' 6 1 and 62 C o r v a i r s
have n o a n t i - r o l l b a r s .
I n 1963 a 5/8" b a r
(#3783523) was made av a i l a b l e as an o p t i o n .
A l l 1 9 6 4 ' s were e q u i p ped w i t h 3/4" b a r s and
s i n c e 1965 t h e a n t i - r o l l
diameter.
FIGURE 4
-
-
C o r v a i r F r o n t Suspension
3.
ACQUIRING COMPDNENTS
-
CONTINUED
The s t e e r i n g assembly i s composed o f ,
1. The s t e e r i n g box and s h a f t
2.
R i g h t and l e f t s t e e r i n g arms a t t a c h e d t o
the spindles
3.
I d l e r arm and a t t a c h m e n t
4.
Two a d j u s t a b l e - l e n g t h d r a g - l i n k s ( t i e - r o d s )
5.
Tie-bar
The s t e e r i n g assembly l a removed b y d e t a c h i n g t h e i d l e r
arm and s t e e r i n g box f r o m t h e frame.
NOTE:
T h r o u g h o u t t h i s s e c t i o n we have been s p e a k i n g o f
t h e C o r v a i r s t e e r i n g box.
S h o u l d you d e s i r e an
optimum s t e e r i n g r a t i o , t h e C o r v e t t e S t i n g r a y
s t e e r i n g box can be used.
I f a used f r o n t s u s p e n s i a n / s t e e r i n g assembly i s t o be
used, check t h e r u b b e r b u s h i n g s f o r d e t e r i o r a t i o n , t h e stamped p a r t s f o r d e n t s and t h e s w i v e l s and b a l l - j o i n t s f o r f r e e ,
y e t snug, o p e r a t i o n .
To v e r i f y t h a t t h e s u s p e n s i o n has n o t
been s e v e r e l y "tweakedn check c l o s e l y t h e f o u r crossmember
mounting h o l e s
t h e s e h o l e s s h o u l d be round, n o t e l o n g a t e d ,
fron r i g h t
and t h e y s h o u l d be s e p a r a t e d b y 27-1/2"(+-1/16")
s i d e t o l e f t aide.
A l s o , s i g h t a c r o s s t h e t o p s o f t h e shock
absorbers, from side-to-side,
t o see t h a t t h e croasaember i s
not twisted
shock a b s o r b e r t o p s a r e s e p a r a t e d 34-5/8"
--
(+-i/eo)
. --
V-8 ENGINE AND BELLHOUSING
The V a l k y r i e K i t i s d e s i g n e d t o most r e a d i l y a c c ~ p ta
or
C h e v r o l e t 283/327 c u b i c i n c h d i s p l a c e m e n t (CID) e n g i n e
a l t e r n a t i v e l y , a F o r d 289 C I D e n g i n e on s e c i a i o r d e r . The
w.Chevyw e n g i n e s have been a v a i l a b l e s i n c %
e
a ~ e
quite
easy t o o b t a i n f r o n d e a l e r s , e n g i n e r e - b u i l d e r s ( i n s h o r t b l o c k form) o r from wreckers.
The horsepower r a n g e o t t h e
283/327 s e r i e s o f e n g i n e s i s 185 HP t o 360 HP
the l a t t e r
f i g u r e b e i n g t h e maximum recommended f o r a p p l i c a t i o n t o t h e
Corvair transaxle.
--
--
A t y p i c a l C h e v r o l e t 327 CID, V - 8 e n g i n e , w i t h approp r i a t e b e l l - h o u s i n g a t t a c h e d i s shown i n F i g u r e 5 on t h e
( ~ o t ea l s o t h e m o u n t i n g o f t h e c l u t c h s l a v e n e x t page.
cylinder).
The f o u r - b o l t p a t t e r n a t t h e r e a r o f t h e b e l l housing shorn i n Figure 5 i s the only p a t t e r n s u i t a b l e f o r
both Chevrolet castuse w i t h t h e F i b e r f a b a d a p t e r p l a t e s
i r o n and d i e - c a s t aluminum b e l l - h o u s i n g s have t h i s p a t t e r n .
--
3.
A C Q U I R I N G COmPONENTS
-
CONTINUED
Remember t o i n c l u d e i n y o u r e n g i n e purchase,
1. The s t a r t e r m o t o r
2.
An a l t e r n a t o r o r g e n e r a t o r
3.
Clutch
4.
Clutch cover
5.
Throw-out b e a r i n g and t h r o w - o u t b e a r i n g arm
6.
Throw-out b e a r i n g g u i d e , t y p e T89B-6 (make
sure t h e mounting flange f o r t h i s guide f i t s
snugly i n t h e h o l e i n t h e r e a r o f t h e bell-housinc
OTHER M A J O R mECHANICAL COmPONEMTS
m e c h a n i c a l components a r e r e q u i r e d t o comKit.
Some " b i t s and p i e c e s n a r e :
--
1.
Brake and c l u t c h p e d a l assembly
we recommend
"Dual Pendulum Pedals," f r o m Honest C h a r l e y , Chattanooga, Tennessee.
Honest C h a r l e y ' s p a r t number
i s 78704'.
2.
F r o n t e n g i n e mounts
t h e V a l k y r i e frame i s des i g n e d t o a c c e p t t h e H u r s t " U n i v e r s a l E n g i n e Mounts."
3.
Rear t r a n s m i s s i o n mounts
t h e V a l k y r i e r e a r cover
p l a t e ( s e e F i g u r e 2) i s d e s i g n e d f o r use w i t h t w o
1948-1959 B u i c k D y n a f l o w t r a n s m i s s i o n mounts
( Balkamp #3-5070, Sears C a t a l o g #28 ~ 2 7 0 4 1 ) .
4.
--
--
--
Clutch slave cylinder
1957-1960 F o r d F-100
t r u c k ( ~ a g n e r - L o c k h e e d #FD-24288).
Tha l i s t abova i s n o t an e x h a u s t i v e l i s t o f a l l o t h e r components r e q u i r e d t o complete your Valkyrie.
othernot strictly
m e c h a n i c a l , components a r e m e n t i o n e d t h r o u g h o u t t h e t e x t t h a t
follows.
A l l component r e q u i r e m e n t s , however, a r e summarized
i n a ~ a r t s l i s ta t t h e and a t t h s a e i n s t r u c t i o n s .
4/
ASSEMBLING THE ENGINE/TRANsAxLE U N I T
The assembly o f t h e e n g i n e / t r a n s a x l e u n i t i s a c c o m p l i s h e d
i n several steps:
1. P r e p a r a t i o n o f t h e e n g i n e
2.
I n s t a l l a t i o n o f the Fiberfab drive-shaft
3. P r e p a r a t i o n o f t h e r e a r henger-plate
Assembly o f t h e e n g i n e / g e a r b o x / d i f f e r e n t i a l
4.
i n t o a single u n i t
ENGINE PREPARATION
Assunfngthat you have t h e e n g i n e r e a d y - t o - g o ,
i e . , t h e engine i t s e l f i s prepared t o your s a t i s f a c t i o n
a l l "hop-upn and/o
" d r e s s - u p w i t e m s have been i n s t a l l e d , t h e s t a t i c t i r i n g has been
set, etc.
s e v e r a l t a s k s remain b e f o r e t h e engine u n i t i s ready
t o be c o u p l e d t o t h e t r a n s a x l e .
How t h e H u r s t f r o n t m o t o r mount
s h o u l d be a t t a c h e d .
The c l u t c h p l a t e and c l u t c h c o v e r s h o u l d be
installed.
And t h e b e l l - h o u s i n g s h o u l d be a t t a c h e d w i t h t h e t h r o w
o u t b e a r i n g and arm i n s i d e ( s e e F i g u r e 5 ) .
--
--
FIGURE 5
GEARBOX I N I T I A L DIS-ASSEmBLY
SHIFTIN
FORK
RODS
DETENT
\
HOLE
INSTALLATION OF THE FIBERFAB DRIVE-SHAFT
T h i s s t e ~i n the assemblv o f t h e e n o i n e / t r a n s a x l e i s urobab1t'is i n
l y t h e most t b d i o u s s t e p i n b u i l d i n g t h s d v a l k y r i e K i t .
t h i s s t e p t h a t t h e s t a n d a r d C o r v a i r gearbox i n p u t - g e a r i s r e p l a c ed
by t h e s p e c i a l i n p u t - g e a r / s h a f t m a n u f a c t u r e d by F i b e r f a b .
(NOTE:
There is a $10.00 v c o r e - c h a r g e N added t o t h o p r i c e o f thc
Valkyrie K i t .
R e t u r n t h e C a r v a i r i n p u t - g e a r (sometimes r e f e r r e d
t o a s t h e w c l u t c h - g e a r " ) t o F i b e r f a b and $10.00 w i l l be r e f u n d e d
t o you).
4/
ASSEPlBLING THE ENGINE/TRANSAXLE UNIT
The f o l l o w i n g sequence of o p e r a t i o n s s h o u l d be used t o
complete t h e g s e r / s h a f t i n s t a l l a t i o n .
1. S e p a r a t e t h e gearbox and d i f f e r e n t i e l h o u s i n g by r e moving t h e f o u r r e t a i n i n g b o l t s t h r e a d e d i n t o t h e
d i f f e r e n t i a l housing.
2.
Remove t h e g e e r b o x f r o n t c o v e r p l a t e ( s i x b o l t s '65,
f o u r b o l t se.6
7
)'6,'
g e a r ( w i t h t h e s p l i n e d hub)
d i r e c t l y u n d e r t h i s c o v e r i s t h e g e a r t o be r e p l a c e d .
3.
Remove t h e g e a r b o x s i d e c o v e r p l a t e ( e i g h t b o l t s '65,
1966-67 gearboxes have t h e
seven b o l t s '66,'67).The
s h i f t i n g f o r k s and r o d s a t t a c h e d t o t h e s i d e c o v e r
p l a t e and t h e y a r e removed w i t h t h e p l a t e .
The 1965
gearboxes have t h e s h i f t i n g f o r k s and r o d s s e p a r a t e
f r o m t h e s i d e c o v e r and t h e y must be removed as desc r i b e d i n s e c t i o n s 4-8 below.
Looking through t h e s i d e opening (see F i g u r e 6 ) .
4.
D r i v e o u t t h e r o l l - p i n s which secure t h e s h i f t i n g
f o r k s t o the s h i f t i n g f o r k rods
i f the pins f a l l
i n t o t h e case, t h e y can be r e t r i e v e d s u b s e q u e n t l y .
--
5.
Remove t h e p l u g f r o m t h e d e t e n t h o l e ( s e e F i g u r e 6 )
and e x t r a c t t h e d e t e n t and s p r i n g n o t i n g
- the order
i n w h i c h t h e y a r e removed.
SHIFTING
SHIFTING
FIGURE 7
GEAR B O X
END V I t W
SHIFTING
ROD
sb
4/
ASSEMBLING THE ENGINE/TRANSAXLE UNIT
r o d #1 c c r n p l e t e l y o u t o f t h e case.
6.
Drive shifting-fork
7.
D r i v e s h i f t i n g - f o r k r o d #2 ( s e e F i g u r e 7) t o t h e p o s i t i o n shown i n F i g u r e 6.. Do n o t remove t h e r o d because
i t r e t a i n s d e t e n t b a l l s and s p r i n g s a t t h e f r o n t o f t h e
case.
8.
Remove t h e t w o s h i f t i n g - f o r k s .
9.
Remove t h e s n a p - r i n g f r o m t h e hub o f t h e i n p u t - g e a r .
10.
Remove t h e i n p u t - g e a r b e a r i n g b y t a p p i n g i t o u t o f t h e
case and s l i d i n g i t o v e r t h e i n p u t - g e a r hub.
11.
Remove thm o u t p u t - s h a f t ( s e e F i g u r e 8 ) b e a r i n g i n i t s
r e t a i n e r (1965 o u t p u t - s h a f t b e a r i n g r e t a i n e r s a r e h e l d
i n p l a c e by two snap-rings.
1966-67 r e t a i n e r s a r e
maintained i n p o s i t i o n w i t h l o c k i n g tabs).
As t h e r e take
t a i n e r l e a v e s t h e case so w i l l t h e m a i n s h a f t
c a r e t o remove t h e m a i n s h a f t and i n p u t - g e a r a s a u n i t .
--
12.
N o t e t h e l o c a t i o n and o r i e n t a t i o n o f t h e b r a s s s y n c h r o the
mesh cone a d j a c e n t t o t h e I n p u t - g a a r . ~ow-draw
t h e i n p u t - g e a r Prom t h e m a i n s h a f t .
Do t h i s o v e r a
c l e a n r a g because a number of n e e d l e b e a r i n g s w i l l f a l l
o u t o f t h e i n p u t - g e a r hub.
FIGURE
OUTPUT
SHAFT
BEARING
OUTPUT
SHAFT
8
STANDARD m A I N SHAFT dr FIBERFAB INPUT GEAR/SHAFT
4/
ASSEMBLING THE ENCINE/TRANSAXLE
UNIT
13.
--
C o l l e c t a l l t h e needle bearings
t h e r e a r e t w o rows
o f n e e d l e s w i t h i n t h e i n p u t - g e a r hub.
Coat t h e i n s i d e
o f t h F~i b e r f a b g e a r / s h a f t hub w i t h as " s t i c k y " g r e a s e
Now p l a c e t h e n e e d l e s i n t h e
as you have a v a i l a b l e .
hub u s i n g t h e g r e a s e t o h o l d t h m i n p o s i t i o n
the
t w o rows s h o u l d be f u l l , w i t h no gaps.
--
14.
S l i d e t h e s y n c h r o r i n g on t h e m a i n s h a f t i n t o t h e pos i t i o n shown i n F i g u r e 8.
Place t h e braas synchro
cone i n t h e i n p u t g m a r / s h a f t .
15.
Next, v e r y c a r e f u l l y i n s e r t t h e m a i n s h a f t and t h e i n p u t - g e a r / s h a f t i n t o t h e g e a r b o x case as shown i n F i g move t h e g e a r / s h a f t c a r e f u l l y t o a v o i d d r o p p i n g
u r e 9.
t h e s y n c h r o cone o r d i s l o d i n g t h e n e e d l e b e a r i n g s ,
B r i n g t h e s h a f t s t o g e t h e r and i n t o a l i g n m e n t .
Insert
t h e nose o f t h e m a i n s h a f t i n t o t h e n e e d l e c l u s t e r s i n
i n t h e g e a r / s h a f t hub.
FIGURE 9
GEARBOX SHOWING
SHAFT ENTRY ANGL
INPUT
GEAR/SHAF
16.
I n s e r t t h e main s h a f t b e a r i n g r e t a i n e r i n t o p l a c e
i n t h e gearbox.
S l i p t h e input-qear b e a r i n g over
t h e g e e r / s h a f t and i n t o t h e gearbox.
I f t h e bearings seat properly i t indicates
t h e main s h a f t
and g e a r / s h a f t have been p r o p e r l y mated.
Reinstall
the bearing retainers
both bearings.
--
17.
R e i n s t a l l t h e s h i f t i n g f o r k s and r o d s , a n d
cover p l a t e .
Use a new g a s k e t .
18.
B o l t t h e gearbox t o t h e d i f f e r e n t i a l housing.
the side
T h i s completes t h e i n s t a l l a t i o n o f t h e i n p u t gear/shaft.
4/
ASSEflBLING THE ENGINE/TRANSAXLE U N I T
PREPARATION OF THE R E A R HANGER PLATE
The rmar h a n g e r p l a t e comes t o you as s h o r n i n F i g u r e 2
i t i s t h e c a s t i n g w i t h t h e l a b e l "FIBERFAB."
Although t h e
h a n g e r - p l a t e i s "as c a s t " when d e l i v e r e d , i t i s t r a n s f o r m e d
i n t o a f i n i s h o d p a r t simply by d r i l l i n g t e n holes.
--
F i r s t , d r i l l and t e p t h e r e c t a n g u l a r bosses s u c h t h a t t h e
B u i c k Dynaflow r u b b e r mounts can be a f f i x e d t o t h e i r b o t t o m s u r faces.
The mounts a r e a t t a c h e d b y b o l t i n g t h r o u g h t h e i r m e t a l
mounting f e e t
3/8" b o l t s a r e a p p r o p r i a t e .
Now p l a c e t h e
h a n g e r p l a t e o v e r t h s r e a r o f t h e t r a n s a x l e , e n g a g i n g t h e 13"
O.D. l i p oQ t h e t r a n s a x l e i n t h e 1 3 " I.D. r e c e s s i n t h e back
surface o f the plate.
A l i g n t h e contours o f t h e p l a t e w i t h the
c o n t o u r s o f t h e t r a n s a x l e . . D r i l l t h e hanger p l a t e f o r a t t a c h mont t o thm t r a n s a x l e u s i n g t h s t r a n s a x l e as a d r i l l j i g
a g a i n 3/8" b o l t s a r e a p p r o p r i a t e .
F i n a l l y , t h e "m"-shaped
r e a r s u p p o r t i s b o l t e d t o t h e r v b b e r mounts.
--
--
The t a s k s i n v o l v e d i n p r e p a r i n g and m o u n t i n g t h e r e a r
h a n g e r p l a t e a r e summarized p i c t o r i a l l y i n F i g u r e 10.
Note
t h a t t h e r e a r s u p p o r t i s n o t welded o r b o l t e d t o t h o f r a m e
u n t i l the e n t i r e d r i v e - t r z i s i n position.
FINAL D R I V E - T R A I N
ASSEABLY
F i g u r e 10 shows a n e x p l o d e d v i e w o f t h e e n g i n e / b e l l housing-to-transaxle interface.
Referring t o t h i s Figure
t h e Fiberfab adapter p l a t e i s b o l t e d t o t h e f r o n t o f t h e
gearbox case.
T h i s j o i n t r e q u i r e s n o g a s k e t b u t s h o u l d be
c o a t e d w i t h a n o n - h a r d e n i n g g a s k e t cement.
Note t h a t t h e h o l e s
l a b e l l e d 1,2,3 and 4 a r e used s u b s e q u e n t l y f o r b o l t s i n t o t h e
h o l e 1 s h o u l d have a b o l t i n i t b e f o r e t h e abellhousing
d a p t e r i s a t t a c h e d p e r m a n e n t l y t o th:? gearbox because once a t tachment i s c o m p l e t e , accoss t o t h i s h o l e i s i m p a i r e d .
--
--
P l a c e t h e T89B-6 t h r o w - o u t ( T / O ) b o a r i n g u i d e m o u n t i n g
f l a n g e i n t h e recess i n t h e adapter p l a t e .
Two o f t h e h o l e s
i n the flange w i l l requiro s l i g h t elongation with a f i l e i f
a '65 t r a n s a x l e i s used
one h o l e r e q u i r e s m o d i f i c a t i o n w i t h
'66-'67 t r a n s a x l e s ) .
Pass f o u r 5/1611-18 b o l t s
at least
1-1/2" l o n g
through t h e mounting flange, through t h e adapter
p l a t e and i n t o t h e gearbox case.
Now, pass t h e r e m a i n i n g b o l t s
t w o 3/8"-16 and one 7/161f-14
( f o r ( 6 5 cases: t w o S/16"-18,
a l l a t l e a s t 1-1/4" l o n g
f o r '66,'67 cases f o u r 3/€Iw-16
a t l e a s t 1-1/4" l o n g ) t h r o u g h t h e a d a p t e r i n t o t h e g e a r b o x
case and t i g h t e n a l l b o l t s .
9
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--
--
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F I G U R E 10
4/
ASSEMBLING THE ENGINE/TRANSAXLE UNIT
To c o m p l e t e t h e d r i v e t r a i n assembly t h e a d a p t e r p l a t s
i s now b o l t e d t o t h e b e l l - h o u s i n g .
Engage t h e T/O b e a r i n g
Cuide t h e nose o f t h e g e a r / s h a f t
g u i d e i n t h e T/O b e a r i n g .
i n t o t h e p i l o t b e a r i n g i n t h e end o f t h e e n g i n e c r a n k s h a f t
and, s i m u l t a n e o u s l y , g u i d e t h e T / O b e a r i n g m o u n t i n g f l a n g e
i n t o t h e h o l e i n t h r~e a r o f t h e b e l l h o u s i n g .
Pass b o l t s
t h r o u g h h o l e s 2,3 and 4 i n t h e a d a p t e r ( h o l a 1 s h o u l d a l r e a d y
r e f e r t o F i g u r e ll),
thread i n t o the b e l l contain a b o l t
h o u s i n g and t i g h t e n .
--
The assembled d r i v e - t r a i n s h o u l d nom c o n s i s t ,
t o - r e a r , of:
1.
2..
3.
4.
5.
6.
7.
from f r o n t -
H u r s t U n i v e r s a l E n g i n e Mount
V-8 engine
Ballhousing
A d a p t ~ rp l a t e / c e n t r a l d r i v e - t r a i n hanger
G~arbox
Differential
Rear c o v e r p l a t e / r e a r d r i v e - t r a i n mounts
5/
INSTALLING THE FRONT SUSPENSION
I n s t a l l i n g t h e f r o n t s u s p e n s i o n on y o u r V a l k y r i e c h a s s i s
i s a very simple operation.
Four b o l t s , 2 on e a c h s i d e , ( a t
l e a s t 3/8" d i a m b t e r and 5 - 1 / ~ l~o n~g ) a r e passed down t h r o u g h
t h e suspension mounting h o l e s i n t h e frame f o r w a r d - s i d e - r a i l s
j u s t ahead o f t h e most f o r w a r d crossmember.
These b o l t s a r e
n e x t en aged i n t h e f o u r h o l e s i n t h e C o r v a i r s u s p e n s i o n c r o s s Lockwashers and n u t s a r e t h e n p l a c e d
member
see F i g u r e 4).
on t h e f o u r b o l t s and t h e n u t s a r e t i g h t e n e d v e r y s e c u r e l y .
?
I f t h e f r o n t s u s p e n s i o n was p u r c h a s e d d i s a s s e m b l e d , i t
can now be assembled on t h e ends o f t h e s u s p e n s i o n crossmemb e r as shown i n F i g u r e 12.
(The k i n g p i n s s h o u l d i n c l i n e back; i e . , t h e t o p
o f t h e k i n g p i n s h o u l d be
b e h i n d i t s b o t t o m ; and
t h e s t e e r i n g arms s h o u l d
be a t t a c h e d t o t h e k i n g p i n s such t h a t t h e arms
p o i n t forward).
FIGURE 1 2
FRONT SUSPENSION ASSEMBLY
No p r o v i s i o n i s mads on t h e frame t o mount any p a r t i c u l a r s t e e r i n g box inasmuch as many c o n s t r u c t o r s may w i s h t o
uee a r a c k and p i n i o n s t e m r i n g arrangement such as i s a v a i l a b l e i n M o r r i s m i n o r , e t c . o r t h e y may w i s h t o usm some q u i c k s t e e r i n g box o t h e r t h a n C o r v a i r .
We have found a t t h e f a c t o r y
t h a t that optimum s t e e r i n g s e t - u p
i n t e r m s o f ease o f i n i s the Corvette
s t a l l a t i o n and h i g h q u a l i t y o f p e r f o r m a a c e
S t i n g r a y ( ' T o r l a t e r C h e v r o l e t C o r v e t t e ) s t e e r i n g box coupl e d with a modified Corvair linkage.
The C o r v e t t e s t e e r i n g
box i s e s p e c i a l l y a d a p t a b l e becausm i t i s p r o v i d e d w i t h a
f l e x i b l e - j o i n t i n p u t - s h a f t - c c u p l i n g w h i c h a l l o w s masy subseq u e n t l o c a t i o n of t h e s t e e r i n g s h a f t r e l a t i v a t o t h e dashboard i n t h e c o c k p i t .
--
--
The s t e e r i n g box i s b o l t e d t o t h e i n s i d e of t h e l e f t ,
f o r w a r d s i d e - r a i l and t h e i d l e r arm s u p p o r t i s b o l t e d t o a
p i e c e o f 1-1/2" x 1-1/2" x 5 " " x 1/8" s t e e l a n g l e w h i c h i n
turn i s b o l t e d t o t h e i n s i d e of t h e r i g h t , f o r w a r d s i d e - r a i l .
To accomodate t h e V a l k y r i e t r a c k and frame d i m e n s i o n s , t h e
C o r v a i r c r o s s l i n k must be s h o r t e n e d t o 24-1/2" ( c e n t e r - t o c e n t e r between t h e i d l e r arm and p i t m a n arm p i c k u p p o i n t s .
ms shown i n F i g u r e 13.
5/
INSTALLING THE FRONT SUSPENSION
FIGURE 13
T I E ROD
*?'
.
::
CROSSLINK
The s h o r t e n i n g i s b e s t a c c o m p l i s h e d b y c u t t i n g and weldi n g w i t h low-hydrogen
rod.
When t h e c r o s s l i n k i s c u t and
rewelded, p e r f e c t alignmmnt i s e s s e n t i a l .
To l o c a t e t h e m o u n t i n g p o s i t i o n s f o r t h e s t e e r i n g box
and t h e i d l e r arm b r a c k e t , s e t t h e wheels p a r a l l e l and a t r a i g h t
ahead, s e t t h e t i e r o d s t o e q u a l l e n g t h a ( a b a u t midway
nountmd on i t s
i n i t s t u r n i n g r a n g e ) . Engage t h e i d l e r arm
b~acket
and t h e p i t m a n arm ( t h e arm on t h e s t e e r i n g box w i t h t h e r i g h t and l e f t ends, r e s p e c t i v e l y , c? t h e
modified crosslink.
Now, t h e i d l e r arm and s t m e r i n g box a r e
s i m u l t a n e o u s l y p o s i t i o n e d on t h e f r a m e r a i l s (usm l a r g e Cclamps o r e q u i v a l e n t , t o t e m p o r a r i l y h o l d t h e s e components i n
p l a c e ) s u c h t h a t t h e i d l e r arm and p i t m a n arm a r e s y m m e t r i c a l
t o t h e c h a s s i s c e n t e r l i n e , i n p l a n ( t o p ) view, and t h e c r o s s l i n k i s p e r p e n d i c u l a r t o t h e c h a s s i s c o n t e r l i n e ( s e e F i g u r e 14).
I n a d d i t i o n , t h e p i t m a n arm and i d l e r arm s h o u l d be p a r a l l e l
i n s i d e v i e w and s h o u l d be b o t h n e a r l y p a r a l l e l w i t h thm " r o a d
surface."
When t h e t h r e e c o n d i t i o n s m e n t i o n e d above arm s a t i s f i e d , p e r m a n e n t l y a t t a c h t h e s t e e r i n g box and i d l e r arm b r a c k e t
t o thm frame.
mountin7
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--
I t s h o u l d be n o t e d t h a t t h e t h r e e c o n d i t i o n s p l a c e d on t h e
l o c a t i o n o f t h e s t e e r i n g l i n k a g e c a n be s a t i s f i e d u s i n g t h e
The C o r v a i r box,
C o r v a i r s t e e r i n g box and m o d i f i e d c r o s s l i n k .
however, has one m a j o r drawback: t h e a x i s - o f - r o t a t i o n o f t h e
p i t m a n arm i s n o t p a r a l l e l w i t h t h e s t e e r i n g box m o u n t i n g s u r face.
Hence, thm box c a n n o t be mounted d i r e c t l y on t h e i n n e r
s u r f a c e of' thm a i d e - r a i l
t h e r a i l m u s t be i n d e n t m d t o accomod a t e t h e C o r v a i r box.
Note, t o o t h a t o n l y ' 6 6 , ' 6 7 C o r v a i r
s t e e r i n g baxes have f l e x i b l e j o i n t s i n t h e s t e e r i n g s h a f t
e a r l i e r u n i t s w o u l d r e q u i r e t h a t t h e s h a f t s be c u t and a U - j o i n t
inserted.
19
--
--
--
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FIGURE 14
6/
INSTALLING THE ENGINE/TRANSAXLE/REAR
SUSPENSION
I n S e c t i o n 4 o f t h e s e i n s t r u c t i o n s , assembly p r o c e d u r e s
a r e g i v e n w h i c h when c o m p l e t e d , y i e l d a V a l k y r i e d r i v e - t r a i n
ready f o r i n s t a l l a t i o n i n t h e frame.
This section describes
t h e i n s t a l l a t i o n o f t h e d r i v e - t r a i n and t h e a t t a c h m e n t o f t h e
r e a r s u s p e n s i o n e l e m e n t s t o i t ( d r i v e - t r a i n ) and t h e c h a s s i s
t h e e l e m e n t s we r e f e r t o a r e a l l shown i n F i g u r e 3.
--
Prior t o the actual i n s t a l l a t i o n o f the driva-train, the
c e n t r a l d r i v e - t r a i n - s u p p o r t cross-member i s removed from t h e
This crossc h a s s i s by b r e a k i n g t h e temporary r e t a i n i n g welds.
member i s t h e n a t t a c h e d t o t h e b e l l h o u s i n g - t o - g a a r b o x a d a p t e r
p l a t e v i a a b o l t t h r o u g h t h e r u b b e r b u s h i n g i n t h e p l a t e and
t h r o u g h t h e m o u n t i n g t a b a t t h e c e n t e r of t h e crossmember.
Once t h e crossmember i s a t t a c h e d t o t h e a d a p t e r , t h e d r i v e t r a i n can be p o s i t i o n e d i n t h e c h a s s i s s u c h t h a t t h e HURST f r o n t
m o t o r mounts r e s t on t h e p a d e s t a l s p r o v i d e d on t h e f r a m e and
mount r e s t s as shown i n F i g u r m 10.
Loand t h a t t h e r e a r If-"
c a t e t h e c e n t e r o f t h e r e a r m o u n t i n g p l a t e 1-114" t o t h e l e f t
of t h e c e n t e r - l i n e ( t h i s o f f - c e n t e r l o c a t i o n r e s u l t s f r o m t h e
asymmetry of t h e C o r v a i r r i n g a n d p i n i o n
t h e p i n i o n gear
s h a f t i s n o t c e n t e r e d between t h e a x l e s , i t i s 1-1/4" c l o s e r t o
the left-axle).
The c e n t e r - l i n e of thm d r i v e - t r a i n ( i e . , t h e
a x i s of t h e c r a n k s h a f t ) i s i n c l i n e d s l i g h t l y w i t h r e s p e c t t o
t h m c h a s s i s c e n t e r - l i n m and, i n t u r n , t h e base o f t h e "mu
p l a t e i s n o t p a r a l l e l w i t h t h e frame member upon w h i c h i t r m s t s
( n o t e , however, t h a t t h e i n c l i n a t i o n does n o t exceed 15 dmqrees
end i t s e f f e c t on t h e o p e r a t i o n of t h e a x l e u n i v e r s a l - j o i n t s i s
negligible).
--
U i t h thm H u r s t m o t o r mount b o l t e d t o t h e frame m o u n t i n g p l a t a b o l t e d o r welded i n p l a c e , t h e
p e d e s t a l s and t h e
r e a r o f t h e d r i v e - t r a i n s h o u l d be l i f t e d u n t i l t h e r e a r r u b b e r
mounts show a s l i g h t r e d u c t i o n i n c o m p r e s s i o n ( i e . , t h e i r
"bulgew i s s l i g h t l y reduced) i n d i c a t i n g a l e s s e n i n g i n t h e l o a d
With t h e d r i v e - t r a i n i n t h i s " l i f t e d " pothey are supporting.
s i t i o n , thm c e n t r a l d r i v e - t r a i n s u p p o r t crossmember, and t h e
f l a n g e s t o w h i c h i t was f o r m e r l y welded, can be d r i l l e d ( t w o
5/16" h o l e s p e r f l a n g e ) and t h e crossmember b o l t e d i n p l a c e .
The d r i v e - t r a i n can now be r e l e a s e d f r o m i t s l i f t e d p o s i t i o n .
The p u r p o s e o f t h e " l i f t i n g u p r o c e d u r e d e s c r i b e d above i s
Ift h i s s u p p o r t were t o be i n t o load t h e c e n t r a l support.
s t a l l e d w i t h o u t l i f t i n g t h s d r i v e - t r a i n , i t would c a r r y n o l o a d
and would have l i t t l e u s e as a s u p p o r t i n g member.
Inasmuch as
t h e d r i v e - t r a i n i s n e a r l y 50" l c n g and weighs a b o u t 500 pound5
i t must be s u p p o r t e d a t i t s c e n t e r
hence. t h e lift in^ p r o c e d u r e must be p e r f o r m e d t o g u a r a n t e e t h e l o a d i n g on t h e c e n t r a l
support,
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6/
INSTALLING THE ENGINE/TRANSAXLE/REAR
SUSPENSION
Next, t h e r i g h t and l e f t r a d i u s - a r m s , a x l e s , suspens i o n l i n k s , b r a k e s and s h o c k - a b s o r b e r s can be assembled
i n t o two ~ r n i t s( t h e s e t w o u n i t s a r e shown i n F i g u r e 3, b u t
F o r purposes o f t h e p h o t o g r a p h t h e r i g h t - h a n d u n i t i s shown
Now, t h e
on t h e l e f t and t h e l e ? t - h a n d u n i t on t h e r i g h t ) .
i n n e r ends o f t h e a x l e s a r e engaged w i t h t h e u n i v e r s a l - j o i n t
f o r k s p r o j e c t i n g from t h e s i d e s o f t h e d i f f e r e n t i a l housing,
and a r e b o l t e d i n p l a c e .
The l o w e r s u s p e n s i o n l i n k p i c k - u p
b r a c k e t s a r e b o l t e d t o t h e b o t t o m o f t h e d i f f e r e n t i a l housi n g and t h e i n n e r ends o f t h e s u s p e n s i o n l i n k s a r e t h e n b o l t ed i n t h e b r a c k e t s .
The c a s t - a l u m i n u m r a d i u s arm h a n g e r s
( s e e F i g u r e 2) a r e b o l t e d t o t h e ends o f t h e r a d i u s arms and
t h e n t e m p o r a r i l y clamped t o t h e m o u n t i n g pads on t h e s i d e s o f
t h e frame.
The s p r i n g s a r e p l a c e d on t o p o f t h e r a d i u s arms
( s e e F i g u r e 3) and t h e i r u p p e r , e n d s a r e p l a c e d i n t h e p p r i n g
r e t a i n e r a b o l t e d t o t h e ends o f t h e r e a r f r a m e crossmember
( t h e s p r i n g r e t a i n e r s s h o u l d be midway i n t h e i r a d j u s t m e n t
range).
Wheels and t i r e s s h o u l d now be b o l t e d t o t h e b r a k e drums
-f r o n t and r e a r -- and t h e w e i g h t of t h e c h a s s i s s u p p o r t e d
on t h e t i r e s t h r o u g h t h e s p r i n g s .
With t h e r e a r s p r i n g s compressed, t h e s h o c k - a b s o r b e r s c a n be a t t a c h e d t o t h e i r f r a m e
m o u n t i n g pads a t t h e ends of t h e r e a r crossmember o p p o s i n g
t h e s p r i n g r e t a i n e r s (once i n s t a l l e d , t h e shock-absorbers
s e r v e t o r e t a i n t h e s p r i n g s when t h e w e i Q h t of t h e c h a s s i s
i s removed).
F i n a l l y , thn t e m p o r a r y clamps h o l d i n g t h e r a d i u s arm
The r a d i e s arms s h o u l d seek
hangers i n p l a c e a r e removed.
t h e i r "preferredw s t a t i c orientation.
Some " p u s h i n g and
s h o v i n g u may be r e q u i r e d t o a c h i e v e t h i s o r i e n t a t i o n i f t h e
rubber bushings throughout t h e suspension took a s e t d u r i n g
t h e i n i t i a l assembly o f t h e s u s p e n s i o n elements.
When t h e
r a d i u s arm h a n g e r s a r e i n p o s i t i o n as shown i n F i g u r a 15,
d r i l l t h e m o u n t i n g pad t h r o u g h t h e hanger, u s i n g i t as a
d r i l l jig.
7/
COmPLETINC THE C H A S S I S PREPARATION
When y o u f i n i s h t h e c o n s t r u c t i o n p r o c e d u r e s g i v e n i n
S e c t i o n 6, y o u r V a l k y r i e K i t c h a s s i s i s c o m p l e t e
t h e frame,
f r o n t and r e a r s u s p e n s i o n s , and d r i v e - t r a i n have a l l been assembled t o g e t h e r .
However, b e f o r e t h e V a l k y r i e body c a n be
mounted on t h e c h a s s i s , p r e p a r a t i o n m u s t be made f o r ,
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1.
2.
3.
4.
The
The
The
The
h y d r s u l i c system
f u e l system
c o a l i n g system
s h i f t i n g linkage
THE HYDRAULIC SYSTEM
The h y d r a u l i c s y s t e m f o r t h e V a l k y r i e i s c o m p r i s e d o f :
1. D u a l m a s t e r c y l i n d e r , pendulum p e d a l u n i t
one st C h a r l e y #78704)
2.
Wheel c y l i n d e r s
integral parts of the
C o r v a i r brake8
3.
C l u t c h s l a v e c y l i n d e r (eg.,
1957-1960 F o r d
F-100 t r u c k )
4.
F i v e f l e x i b l e h y d r a u l i c hoses
5.
Ten s e c t i o n s o f v a r i o u s l e n g t h s o f s t e e l o r
c o p p e r t u b i n g ; a p p r o x i m a t e l y 40 f e e t t o t a l
6.
F i v e tubing-to-hose adapter f i t t i n g s
7.
Four T E E - f i t t i n g s
8.
Twenty m a l e t u b i n g - t e r m i n a t i n g f i t t i n g s ( a l l
t u b i n g f i t t i n g s s h o u l d be f l a r e - t y p e , n o t
ferrule-type)
9.
Three dozen p l a s t i c t u b i n g hold-down clamps
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t h e m a s t e r c y l i n d e r assembly
R e f e r r i n g t o F i g u r e 16
i s mounted, u s i n g a s t e e l - p l a t e a n g l e - b r a c k e t , t o t h e t o p o f
t h o f r o n t 3" x 1-1/2" crossmember.
From t h e b r a k e m a s t e r
c y l i n d e r , t u b i n g i s r o u t e d t o a T E E - f i t t i n g mounted n e a r t h e
From t h e T E E - f i t t i n g t u b i n g i s
c e n t e r o f t h e crossmember.
r o u t e d as shown i n F i g u r e 16.
The f l e x i b l e hose c o u p l i n g t h e f r o n t w h e e l c y l i n d e r s t o
t h e t u b i n g on t h e f r a m e m u s t be o f s u f f i c i e n t l e n g t h t o a l l o w
u n r e s t r i c t e d t u r n i n g , bounce and re-bound o f t h e f r o n t wheels
r e s t r i c t t h e m o t i o n o f t h e hose o n l y t o a v o i d a b r a s i o n o f
t h e hose on s u s p e n s i o n components.
The t u b i n g t o t h e r e a r
b r a k e s and c l u t c h s l a v e c y l i n d e r i s f a s t e n e d w i t h hold-downs
a l o n g t h e o u t s i d e o f t h e frame.
The f l e x i b l e hoses t o t h e
r e a r b r a k e s a r e j u s t l o n g enough t o b r i d g e t h e r a d i u s arm
"hingew
t u b i n g i s r u n a l o n g t h e t o p o f each r a d i u s arm t o
t h e wheel c y l i n d e r s t o c o m p l e t e t h e r e a r b r a k e h y d r a u l i c c i r A t some p o i n t i n t h e t u b i n g between t h e r e a r b r a k e s
cuits.
a T E E - f i t t i n g s h o u l d be i n s e r t e d t o accawodate a b r a k e - l i g h t
ptessure-switch
w i r i n g d e t a i l s f o r t h i s stuitch are given
i n S e c t i o n 9.
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23
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H Y D R A U L I C SYSTEM LAYOUT
CONPLETING THE C H A S S I S PREPARATION
-
CONTINUED
THE FUEL SYSTEB
The V a l k y r i e s p r e p a r e d a t F i b e r f a b have s u c c e s s f u l l y u t i l i z e d s e v e r a l f u e l system c o n f i g u r a t i o n s .
One c o n f i g u r a t i o n
employs s p e c i a l l y - p r e p a r e d gas t a n k s c o n s t r u c t e d t o e x a c t l y f i t
i n t h e t r i a n g u l a r o p e n i n g s i n t h e frame a d j a c e n t t o t h e e n g i n e
bay.
These t a n k s were f a b r i c a t e d of aluminum s h e e t , h e l i - a r c e d
bottom-to-bottom
by a
together.
The t a n k s u e r e j o i n e d
balance tube.
Gas i s d e l i v e r e d from t h e r i g h t - h a n d t a n k t o t h e
m e c h a n i c a l f u e l pump on t h e e n g i n e b l o c k v i a f l e x i b l e hose f r o m
t h e tank bottom.
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A second c o n f i g u r a t i o n u s e s a C o r v a i r gas t a n k mounted J u s t
ahead o f t h e f r o n t s u s p e n s i o n crossmember and j u s t above t h e
The wedge-shape of t h e t a n k i s p o s i t i o n e d such
steering linkage.
t h a t i t d a f l e c t s t h e a i r coming t h r o u g h t h e r e d i a t o r up t h r o u g h
Because t h i s t a n k is q u i t e r e m o t e
t h e a i r v e n t s i n t h e "hood."
f r o m t h e e n g i n e i t i s a d v i s a b l e t o use an e l e c t r i c f u e l pump a t
t h e t a n k t o pump f u e l back t o t h e m e c h a n i c a l punp on t h e e n g i n e .
The f u e l l i n e s h o u l d be r o u t e d as t h e b r a k e t u b i n g ( s e e F i g u r e
be s u r e t o use o n l y
16) b u t on t h e r i g h t s i d e o f t h e frame
s t e e l t u b i n g ; copper t u b i n g i s a t t a c k e d b y t h e a d d i t i v e s i n ga3oline.
Be s u r e , a l s o t o a t t a c h a b o u t f o u r f e e t o f #16 w i r e t o
t h e f u e l - l e v e l sender u n i t t e r m i n a l
t h i s terminal i s relativel y i n a c c e s s i b l e once t h e body i s i n p l a c e .
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A n o t h e r p o s s i b l e l o c a t i o n f o r a f u e l t a n k i s i n t h e spece
above t h e g e a r b o x / d i f P e r e n t i a l h o u s i n g j u s t b e h i n d t h e d r i v e t r a i n c e n t r a l - s u p p o r t and ahead o f t h e r e a r crossmember.
A tank
i n t h i s l o c a t i o n would have t o be r e l a t i v e l y easy t o remove t o
a l l o w o c c a s i o n a l a c c e s s t o t h e d i f f e r e n t i a l cover.
No s u p p l e m e n t a l punp w o u l d be r e q u i r e d .
THE COOLING SYSTEm
The c o o l i n g system f o r t h e V a l k y r i e uses a r a d i a t o r mounted
a t t h e v e r y f r o n t of t h e frame w i t h c o o l a n t c a r r i e d t o and f r o m
t h e e n g i n e b y p i p i n g a l o n g t h e s i d e s o f t h e frame.
The recommended r a d i a t o r i s t h e H a r r i s o n - O e l c o (Gm#3150916) u n i t used i n
C o r v e t t e s s i n c e 1961.
T h i s r a d i a t o r i s mounted i n a 24-1/2" x
2O9I frame c o n s t r u c t e d o f 1" x 1" x 1/8" s t e e l a n g l e .
The Prame
i s a t t a c h e d t o t h e c h a s s i s f r a m e - r a i l s a s shown i n F i g u r e 1 7 and
t o t h e r a d i a t o r as shown i n F i g u r e 18.
Note t h a t t h e r a d i a t o r ,
I n a d d i t i o n , t h e overas used i n t h e V a l k y r i s , i s u side-down.
f l o w p i p e m u s t be p l u g g e d and a s opcoc screwed i n t o t h e " s t o p cock h o l e u
t h e s t o p c o c k i s used as a n a i r - b l e e d when t h e c o o l i n g system i s i n i t i a l l y f i l l e d .
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7/
COmPLETING THE CHASSIS PREPARATION
-
CONTINUED
FIGURE 18
RADIATOR I N SUPPORTING FRAmE
STOPCOC:K HOLE
-.
-
OVERFLOW TUBE
7/
COMPLETING THE C H A S S I S PREPARATION
-
CONTINUED
The g e n e r a l r o u t i n g o f t h e c o o l a n t p i p i n g i s shown i n
F i g u r e 19.
F o r c l a r i t y , t h e p i p e s a r e shown a d j a c e n t t o t h o
s i d e f r a m e - r a i l s when, i n f a c t , t h e y a r e r o u t e d b e n e a t h t h e
frame-rails.
The t u b i n g on t h e r i g h t - h a n d s i d e r e m a i n s ben e a t h t h e frame beyond P o i n t " A " ( s e e F i g u r o 1 9 ) .
The l e f t hand t u b e r i s e s ahead of P o i n t " 8 " (see F i g u r e 1 9 ) up and
i t i s routed t i g h t against the outside
over t h e s t e e r i n g - b o x
The l e f t - h a n d p i p i n g t e r m i n a t e s a t
o f the floorpan/fireuall.
t h e m a n i f o l d c o o l a n t i n l m t and t h e r i g h t - h a n d
piping terminates
a t t h e pump o u t l e t .
The t u b i n g on b o t h s i d e s , however, r e m a i n s
under t h e frame a s i t r u n s i n b o a r d t o w a r d s t h e e n g i n e
flexi b l e hose i s used t o r o u t e t h e c o o l a n t up t o o r down f r o m t h e
engine.
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The c o o l i n g system i s f i l l e d t h r o u g h a 2 f o o t s t a n d p i p e
o v e r f l o w i s accapped w i t h a s t a n d a r d r a d i a t o r p r e s s u r e cap
comodated a t t h i s p o i n t i n t h e system.
The s t a n d p i p e i s " t a p ped" i n t o t h e c o o l i n g system i n t h e l o c a t i o n shown i n F i g u r o 19.
I t p r o j e c t s up f r o m t h e c o o l a n t p i p e s j u s t b e h i n d t h e d r i v e r ' s
seat.
( I f t h i s l o c a t i o n o f t h e standpipe i n t e r f e r e s w i t h your
gas t a n k , a t t a c h t h e s t a n d p i p e f u r t h e r o u t b o a r d and a n g l e i t
i n b o a r d over t h e tank).
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The c o o l a n t system i s c o n s t r u c t e d of t h i n - w a l l s t e e l t u b i n g (exhaust-pipe t u b i n g )
any O.D.
g r e a t e r t h a n 1-1/4" i s
satisfactory.
The r o u t i n of t h e t u b i n g i s a c c o m p l i s h e d by,
b) c a r e f u l bending
avoiding col( a ) c u t t i n g and w e l d i n g ,
lapse o f the tubing, o r ( c ) connecting s t r a i g h t sections w i t h
p i e c e s o f pre-formed r u b b e r hose ( b y " p r e - f o r m e d v we mean s h o r t
s e c t i o n s o f hose p e r m a n e n t l y formed a t d i f f e r e n t a n g l e s ) .
In
any case, p a i n t t h o o u t s i d e o f t h e s t e e l t u b i n g w i t h r u s t - i n h i b i t i n g p a i n t b e f o r e f i n a l assembly and use s t a i n l e s s s t e e l hose
clamps f o r assembly.
9
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Also, i n c o n n e c t i o n w i t h t h e c o o l i n g system, you s h o u l d
saw open t h e a i r i n l e t i n t h e nose o f t h e V a l k y r i e body and
the a i r outlets i n the
I f any s c r e e n i n g o r m e t a l mesh
i s t o be p l a c e d i n t h e o u t l e t s , now is t h e t i m e t o i n s t a l l i t
b e f o r e t h e body i s mounted.
( F i g u r e 19 i s shown on t h e n e x t page.
w i t h s h i f t l i n k a g e b e g i n s on page 29).
The s e c t i o n concerned
t llrUKt
1Y
COOLING SYSTEM LAYOUT
7/
CQDIPLETING THE C H A S S I S PREPARATION
-
CONTINUED
THE SHIFTING LINKAGE
R e f e r r i n g t o F i g u r e 7, t h e C o r v a i r t r a n s m i s s i o n g e a r s a r e
s h i f t e d by r o t a t i n g t h e s h i f t i n g r o d and moving i t i n and o u t of
r o t a t i o n s e l e c t s t h e "1st-2nd,"
"3rd-4th" o r r e t h e gearbox
i n and o u t m o t i o n s e l e c t s 1 s t . 3rd, r e v e r s e
v e r s e gear g a t e s
o r 2nd, 4 t h .
Combining t h e t w o m o t i o n s , s i m u l t a n e o u s l y , a l l o w s
t h e s e l e c t i o n o f any one o f t h e f i v e o e a r s ("4-speed" gearbox).
The purpose o f t h e s h i f t i n g l i n k a g e , t h e n , i s t o t r a n s f e r t h e
b a c k - a n d - f o r t h and s i d e - t o - s i d e m o t i o n 9 f t h e g e a r s h i f t l e v e r ,
i n t h e c o c k p i t , back t o t h e s h i f t i n g r o d and c o n v e r t t h e s i d e to-side notion i n t o rotation.
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The s i m p l e s t means o f t r a n s f e r r i n g m o t i o n s i s v i a "pushp u l l n c o n t r o l c a b l e s s u c h as t h e RED-JAKEI c a b l e s m a n u f a c t u r e d
b y t h a Morse I n s t r u m e n t Company, Hudson, Ohio 44236 ( t h i s add r e s s i s adequate t o c o n t a c t Morse
we recommend y o u p e r u s e
t h e i r c a t a l o g #165 b e f o r e d e s i g n i n g your s h i f t i n g l i n k a g e ) .
F i g u r e 20 i l l u s t r a t e s a p u e h - p u l l c a b l e e o n f i g u r a t i o n a p p l i c a b l e
A s u i t a b l e geart o t h e V a l k y r i e s h i f t i n g l i n k a g e requirements.
s h i f t l e v e r can be e x t r a c t e d from a wrecked Volkswagen ~ e d a n
o r purchased new from a Volkswagen d e a l e r .
The b o t t o m end
o f t h e l e v e r i s m o d i f i e d t o aceomodate t w o Morse A29025 c l e v i s e s
as shown i n F i g u r e 20
t h e s e c l e v i s e s a c c e p t 1/4" m a t e r i a l .
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The g e a r s h i f t i s s u p p o r t e d on a 3/16" s t e e l b r a c k e t welded
o r b o l t e d t o t h e f r o n t o f t h e c e n t r a l frame crossmember a t i t s
center.
The f r o n t edge o f t h e b r a c k e t s h o u l d p r o v i d e a means
t h e " 0 " c a b l e i s clamped t o t h e
of c l a m p i n g t h e " A M c a b l e
crossmember.
The recommended c a b l e s a r e f l o r s e 42C, t h e end8 o f
which clamp w i t h morse A31532 clamps.
Cable " A w i s 1 4 f e e t l o n g ;
c a b l e "En 9 f e e t .
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Cable " A n t r a n s f e r s t h e back-and-Forth m o t i o n o f t h e gear8 h i f t t o in-and-out motion o f the s h i f t i n g r o d a t t h e t r a n s Cable " E n t r a n s f e r s s i d e - t o - s i d e m o t i o n of t h e g e a r mission.
s h i f t t o up-and-down m o t i o n o f t h e end oP a l e v e r a t t a c h e d t o
The up-and-doun m o t i o n a t t h e l e v e r , i n t u r n ,
t h a a h i t t l n g rod.
becomes r o t a t i o n o f t h e s h i f t i n g r o d .
The l e v e r i s f a b r i c a t e d
o f 1/4H s t e e l p l a t e and i s p i n n e d o n t o t h e s h i f t i n g r o d ( i t may
be necessary, depending on t h e i n s t a l l a t i o n , t o c u t away a p o r t i o n of t h e b o t t o m edge o f t h e F i b e r f a b a d a p t e r p l a t @ t o g a i n
clearance ?or t h e l e v e r ) .
Cable " A w i s clamped t o t h e u n d e r s i d e o f t h e gearbox and
r o u t e d under t h e l e f t - a x l e i n n e r u n i v e r s a l j o i n t ,
The " 0 " c a b l e
i s clamped t o t h e r e a r face of t h e F i b e r f a b a d a p t e r p l a t e and
" l o o p e d " up and o v e r t o t h e l e f t - s i d e f r a m e - r a i l a s shown i n
F i g u r e 20.-- m i n i m u m recommended bend r a d i u s i s 8 " .
F I G U R E 20
S H I F T I N G , . L I N K A G E CONFIGURATION
7/
COMPLETING CHASSIS PREPARATION
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CONTINUED
OTHER CONSIDERATIONS
I f c o n s i d e r a b l e d r i v i n g i n t r a t f i c i n warm w e a t h e r i s
contemplated, we a d v i s e t h a t you i n s t a l l an e l e c t r i c f a n ahead o f t h e r a d i a t o r .
A s u i t a b l e fan b l a d e and m o t o r a r e
thosse used b y t h e J a g u a r X-KE.
mount t h e m o t o r on a p l a t form a t t a c h e d t o t h e r a d i a t o r f r a m e s u c h t h a t t h e b l a d e i s
c e n t e r e d i n f r o n t o f t h e r a d i a t o r and as c l o a e t o t h e r a d i a t u r as p o s s i b l e .
The X-KE b l a d e draws a i r a r o u n d t h e m o t o r
reversing
so t h e p i t c h must be r e v e r s e d b y c a r e f u l b e n d i n g
t h e p i t c h f o r c e s a i r away f r o m t h e m o t o r a s d e s i r e d .
Note
t h a t s i m p l y t u r n i n g t h e b l a d e o v e r does n o t r e v e r s e t h e d i by a s w i t c h on
rection of airflow.
The m o t o r - i j e n e r g i t h e dashboard
w i r i n g d e t a i l s a r e g i v e n i n S e c t i o n 9.
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An e x h a u s t system can be i n s t a l l e d a t any t i m e
even
a f t e r t h e body i s mounted.
U n l e s s you p l a n t o f a b r i c a t e y o u r
own e x h a u s t system, we recommend t h a t you u s e t h e casst i r o n
m a n i f o l d s a s shown i n F i g u r e 5 and t a k e y o u r V a l k y r i e t o a
l o c a l e x h a u s t s y s t e m / m u f f l e r s p e c i a l i s t f o r t h e balancm o f
t h e system.
8/
ROUNTING THE BODY
Your V a l k y r i m body i s rmcmived r i t h an i n t e g r a l f l o o r pan a l r e a d y laminatmd i n t o p l a c e i n thm m a i n body s a c t i o n .
T h i s f l o o r p a n was d e s i g n e d i n such a r a y t h a t i t f i t s m x a c t l y
i n t o placm on t h e c h a s s i s , i s . , w i t h t h e g r o o v e s i n thm f l o o r pan i n f r o n t o f , between and t o t h e sidms o f thm m o l d e d - i n
I n sssenem, thm f r a r m " f i t s
s e a t s f i r m l y mngaqing thm franm.
up" i n t o t h e grooves o f t h e f i b e r g l a s s f l o o r p a n .
When thm
body l a p r o p m r l y s e t on thm ?ram.,
i t i s "lockedn i n t o posit i o n by t h a d e s i g n o f thm ? l o o r p a n / s m a t s .
--
Two p e r s o n s s h o u l d bm a v a i l a b l m t o mount thm body
onm on each s i d e l i f t i n g t h e body b y a wheel-opening and t h e
The body s h o u l d be c a r e f u l l y
t o p o f a s i d e window opening.
n j o c k e y e d ~ tback o v e r t h e ?ram@ w i t h s p e c i a l c a r e b e i n g mxerc i s e d as t h e r a d i a t o r e n t e r s t h e nose o f thm body.
Securm
t h a body t o t h e frame u s i n g 1/4" x 1" s h e e t m e t a l acrmws
t h r o u g h thm f l o o r p a n i n t o t h e t o p o f t h e frame
usm r a s h e r s under t h e heads o f t h e screws.
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Also, aecurm thm nose o f thm body t o t h e ?ram. u s i n g
s h e e t mmtal screws t h r o u g h t h e i n n e r p a n e l s i n thm nosm i n t o
No l e s s t h a n
thm frame m x t e n s i o n s s u p p o r t i n g thm r a d i a t o r .
20 scrams s h o u l d be usad
16 i n t h e f l o o r p a n and 4 i n t h e
nose.
--
Nor, a holm can bm b o r e d t h r o u g h t h e u ? i r m w a l l w t o acc e p t t h e s t e e r i n g column.
The column i s passmd t h r o u g h t h e
h o l e u n t i l thm s t m e r i n g s h a f t engagms thm s t a m r i n g b ~ x . The
column i s t h e n clamped i n t h e 9 e v a l l e y vbmtween t h e t w o l a r g m
i n s t r u m e n t s and a l s o a t thm f i r e w a l l .
Thm rmar body s m c t i o n o f thm V a l k y r i e K i t i s dmlivermd
w i t h two hingm-pin sockmts l a m i n a t e d i n t o i t n e a r t h e b o t t o m
edgm a t t h e rmar.
Whsn t h e s e s o c k e t s e r e p i n n e d t o g s t h m r w i t h
thm a d j u s t a b l m hingm p i v o t s ( a t t e c h m d t o thm hangers p r o j m c t i n g f r o m t h a rmar frame crossmenbsr) thm rmar s e c t i o n i s
mounted.
The e a s i e s t method o f adjusting thm hingm p i v a t s i s
t o s e t thm r e a r s e c t i o n i n p l a c e on t h e main s e c t i o n and h e l d
i t i n p o s i t i o n w i t h clamps a l o n g t h e edges o f t h e body s e c t i o n s
j u s t ahmad o f t h e r e a r window opening.
With t h e r e a r s a c t i e n
clampmd, t h e hingm p i v o t s can e a s i l y be a l i g n e d w i t h t h e hingmWhmn a l i g n m e n t i s a c h i e v e d a 3/8" x 2 - l / Z n h i n g a
p i n sockmts.
p i n s h o u l d be insmrtmd t h r o u g h each p i v o t i n t o t h e s o c k e t and
tha pivot securely bolted i n place
now t h e clamps can bm
removmd and thm r e a r s e c t i o n s u p p c r t t a k e n by thm rmar hangars
v i a t h e hinge pins.
--
Rubber bumpers usmd i n t h e C o r v a i r (GM #3732247) arm u t i l i z m d t o c u s h i o n and h e l p a l i g n t h e r e a r a m c t i o n a g a i n a t thm
m a i n body smctlon.
The r e c e p t a c l e f o r t h e bumpar i s a l r e a d y
formed i n t o thm V a l k y r i m .
To usm t h e bunpmr, prmparm i t a r
8/
ROUNTINC THE BODY
- CONTINUED
A 1/4" s t o v e - b o l t ( r o u n d head) i s usmd t o
shown i n F i g u r e 21.
b o l t thm b w p m r t o t h e r e a r smction.
Wm suggmst d r i l l i n g thm
mounting holm s l i g h t l y o v e r s i z e t o a l l o w you t o movm thm bumpmr
f o r p e r f e c t adjuntmmnt.
The r s c m p t a c l e f o r thm bumpmr i n ao
dmsigned t h a t t h e bunpmr must be s w o l l e n b y t i g h t e n i n g thm atovm
bolt.
Bm sure t o usm a r a s h e r undmr t h e n u t .
Wm a l s o ruggmst
d o u b l e - n u t t i n g t h e s t o v e - b o l t s t o i n s u r e t h a t your adjuatmmntn
of r e a r s m c t i o n alignment, oncm made, w i l l rmmain i n t a c t .
FIOURE 2 1
9/
MOUNTING THE ELECTRICAL COMPONENTS
--
WIRING
This s e c t i o n o f t h e i n s t r u c t i o n s provides tho ground-rules
Tha
f o r i n s t a l l i n g t h e e l e c t r i c a l system i n y o u r V a l k y r i a K i t .
c o n f i g u r a t i o n d e s c r i b e d below i s based on t h e f a c t o r y - a s s a n b l e d
w i r i n g h a r n e s s w h i c h has p r o v e d most a d a p t a b l a t o a v a r i e t y o f
angine/lighting/instrumentation c o m b i n a t i o n s .
The c o n f i g u r a t i a n
i s a l s o based on o u r e x p e r i a n c a r e g a r d i n g t h a n o s t c o n v e n i a n t ,
p r a c t i c a l o r s e r v i c a a b l e placement o f e l e c t r i c a l system coaponants.
To b e g i n ,
an e l e c t r i c a l s y s t e a / w i r i n g
harnmsa s h o u l d p r o v i d a :
Engina s t a r t i n g
Engine i g n i t i o n
tamparatura,
Engine i n s t r u m e n t a t i o n
o i l pressure
Ganeral i n s t r u a s n t a t i o n
fuel laval,
battsry/generator condition
Interior lighting
Exterior lighting
Power f o r a c c e s s o r i e s ( s w i t c h e a n t r a l l a d
and/or d i r a c t )
---
A t t h i s s t a g e i n t h a c o n s t r u c t i o n process, many i t e n a t o
ba w i r e d hava a l r a a d y been i n s t a l l e d w i t h t h e d r i v e - t r a i n ( i e . ,
enginm/transexla), viz.,
the starter, startbr-solenoid, i g n i t i o n c o i l , genaratar ( o r a l t e r n a t o r ) , oil-pressure*,
oil-temperature**
(if
used), watmr-tmmperature* aenders and t h a f u a l - l a v e 1 aender
i n t h a gas t a n k
a rsvarse-light switch i s available a t tha
bottom f r o n t o f t h e gsarbox (see F i g u r e 7)
6ee F i g u r e 16 f m r
brake-light switch position.
The f o l l o w i n g i t e m s , however, have
n o t been i n s t a l l e d :
--
--
THE LIST BELOld TABULATES THE ITEMS TO BE INSTALLED PLUS
REHARKS CONCERNING PIOUNTING LOCATION AND RECOIUBENDED
SOURCES ( I F A N Y ) FOR THE ITEM.
1.
--
BATTERY
assuming a f r o n t - m o u n t e d gas t a n k ; i n t h e
t r i a n g u l a r o p e n i n g i n t h e frame on t h e r i g h t s i d e o f
t h e angina
#24 s i z e (10-5/16"
l o n g , 6-3/4n r i d e ,
8-11/16" h i g h ) 1 2 - v o l t b a t t e r y .
--
2.
--
VOLTAGE REGULATOR
on t h e b u l k b a a d (back o f t h e
s e a t s ) t o t h e r i g h t o f t h e engine.
* m a r n i n g l i g h t s w i t c h o r gauga sender u n i t
**sender mounted as r e p l a c e m e n t d r a i n p l u g i n o i l pan
--
34
- 0
9/
MOUNTING THE ELECTRICAL COMPONENTS
3.
--
CONTINUED
--
TAIL LIGHTS/BRAKE
LIGHTS
i n thm r e a r p a n e l o f t h e
rmar body s e c t i o n wherever a p l e a s i n g appearance i s
l a t e model C o r v e t t e S t i n g r a y l i g h t s mountachieved
ad t h r e e p a r a i d e
o u t s i d m p a i r and i n s i d e p a i r used f o r t a i l l i g h t s ( l o w f i l a m e n t , rmd l e n s ) , o u t s i d m
p a i r used as t u r n i n d i c a t o r s ( h i g h f i l a m e n t ) , i n s i d m
p a i r used as b r a k e l i g h t s ( h i g h f i l a m m n t ) and c e n t e r
lens)
p a i r used as back-up l i g h t s ( h i g h f i l a m e n t , w h i t .
note t h a t these l i g h t s c o n s t i t u t e s i x , non-interchangeable u n i t s , i e . , each f i t s i n a p a r t i c u l a r l o c a t i o n ( R H O u t s i d e , LH Center, LH i n s i d e , e t c . ) .
--
--
--
--
4.
FRONT P A R K I N G / T U R N INDICATOR LIGHTS
i n t h a two r e ceseas a d j a c e n t t o t h e nose o p e n i n g i n thm body
late
m o d e l P o n t i a c Gran P r i x o r GTO p a r k i n g l i g h t s .
5.
HEADLIGHTS
i n t h e molded-in recessas provided i n t h e
post-1958 Chevrolet d u a l h e a d l i g h t
V a l k y r i e body
bm s u r e t o p o s i t i o n t h e d u a l f i l a m e n t lamp
units
t o thm o u t s i d e o f t h e body.
--
--
-- --
--
6.
WINDSHIELD WIPER mOTOR
i n t h e upper, r e a r c o r n e r o f
thm r i g h t - s i d e , f r o n t w h e e l - w e l l
any LUCAS w i n d s h i e l d
w i p e r assembly as f o u n d i n Austin-Healmy, Triumph,
etc.
Jaguar ( n o t X-KC),
7.
HEADLIGHT DImmER SWITCH
l e f t o f the c l u t c h pedal
Corvair.
eg.,
8.
HORN
on t h e i n s i d e , f r o n t end o f t h a l e f t - s i d e framer a i l ( a b o u t where t h e r a d i a t o r frame i s a t t a c h e d b u t
any r e l a y - o p e r c l o s e r t o t h e end o f t h e f r a m e - r a i l )
a t e d horn, eg., Mustang.
--
---- onanyt h es t a" nf idraerwd adimmer
llw j u s t t o tha
switch,
--
--
9.
--
HORN RELAY
on t h e l e f t - s i d e s p l a s h p a n e l i n s i d e t h a
f r o n t , l e f t w h e a l - w e l l j u s t above t h e s t e e r i n g - b o x
any s t a n d a r d , t h r e e - t e r m i n a l h o r n - r e l a y , eg., C o r v a i r .
--
--
LO.
COURTESY LIGHT SWITCHES
i n thm d o o r jamb between
t h a hinges i n b o t h door openings
Corvette-type,
two-terminal, flange-mounting switches.
11.
COURTESY LIGHT
i n t h e r a i s e d a r e a between t h e s e a t s .
s u f f i c i e n t l y h i g h t h a t i t i l l u m i n a t e s t h e console area
Corvette courtesy l i g h t .
--
--
--
--
REmEmBER
u n l i k e s t e e l , f i b e r g l a s s i s an i n s u l a t o r ,
Any
m l e c t r i c a l component mounted i n f i b e r g l a s s r e q u i r e s a s e p a r a t e
ground (return-path) wire.
9/
MOUNTING THE- ELECTRICAL COMPONENTS
Your V a l k y r i e K i t
body i s d e l i v e r e d t o
you w i t h a f i b e r g l a s s
dashboard and c o n s o l e
a l r e a d y i n p l a c e (see
F i g u r e 22).
It i s not
n e c e s s a r y f o r you t o
laminate o r otherwise
a t t a c h , t h e dashboard
t o t h e body
this
has been done a t t h e
factory.
The dash i a
designed t o u t i l i z e a
centralized instrumsnt
control cluster
the
c l u s t e r i s t h e hub o f
t h e m i r i n a h a r n e s s and
should b e - c a r e f u l l y
planned.
The s t a n d a r d
i n s t r u m e n t / c o n t r o l conf i g u r a t i o n ussd i n f a c t o r y b u i l t cars i s :
-
CONTINUED
--
--
1.
2.
3.
4,
5.
6.
7,
8,
9,
10,
11.
12.
13.
14.
FIGURE 22
Kay-operated i g n i t i o n s w i t c h ( ~ o c k - 0 f f - o n - s t a r t )
Headlight switch (preferably with provision for
i n s t r u m e n t l i g h t dimming and c o u r t e s y l i g h t c o n t r o l )
Windshield w i p e r s w i t c h (SPST)
Fan s w i t c h ( S P S T )
O t h e r a c c e s s o r y s u i t c h e s as r e q u i r e d
F u e l - l e v e l gauge
Ammeter ( d i s c h a r g e w a r n i n g l i g h t may be s u b s t i t u t e d )
O i l - p r e s s u r e gauge ( w a r n i n g l i g h t may be s u b s t i t u t e d )
O i l - t e m p e r a t u r e gauge ( o p t i o n a l )
W a t e r - t e m p e r a t u r e gauge
Speedometer ( n o n - e l e c t r i c a l e x c e p t f o r l i g h t i n g )
Tachometer ( o p t i o n a l ) *
High-beam i n d i c a t o r l i g h t
T u r n - i n d i c a t o r dash l i g h t s
F o r y o u r c o n v e n i s n c e we have l i s t e d b e l o w t h e numbers o f
t h e STEWART-WARNER gauges and a c c e s s o r i e s used i n t h e f a c t o r y
b u i l t cars,
These i t e m s may be o r d e r e d f r o m your l o c a l r e p r e s e n t a t i v e of Stewart-Warner o r d i r e c t l y f r o m F i b s r f a b .
VALKYRIE 12-VOLT
Ammeter ( g e n e r a t o r )
--
*
S-W NUmBER
D359-CE
PR ICE
$8.45
Ammeter ( a l t e r n a t o r )
0359-CW
8.05
Ths tachornetor ~ o n d s r , ifr o m o t s f r o m t h o gaugo, s h o u l d bo
mounted on t h e r o a r b u l k h e a d n e a r t h e e n g i n e b u t i n an a r e a
which avoids excessively h i g h tmparatuses.
9/
RlOUNTING THE ELECTRICAL COflPONENTS
VALKYRIE 12-VOLT
S-W
NUmBER
-
CONTINUED
PRICE
F u a l l e v e l gauge
F u a l l e v e l sender
Installation k i t
D301-AW
0385-8
366-LP
$11.15
6.20
1.65
Water t a n p e r a t u r e gauge
Watmr t a n p a r a t u r e s e n d e r
D311-CC
D362-BY
11.45
3.15
O i l p r e s s u r e gaugm
O i l preasurm sender
0306-88
0353-2
11.15
7.50
O i l tampmrature gauge
O i l temperature sender
D311-CF
D362-AH
11.45
4.35
Tachometer ( i n t e g r a l
sender)
D960-AA
54.00
L i g h t i n g f o r t h e gauges l i s t e d above i s p r o v i d m d b y
D366-CH lamp k i t s B $1.00 p e r k i t .
--
Tha w i r i n g h a r n e s s i s d i v i d e d i n t o t h r m e m a j o r p i e c e s
thm hub o r dashboard s a c t i o n , t h e h u b - t o - f r o n t h a r n a s s and
t h e hub-to-rear harness.
F i g u r e 23 shams t h e gmnmrel r o u t i n g
of t h e s e h a r n e s s e s r e l a t i v e t o t h e V a l k y r i m frama.
The h u b - t o - r e a r h a r n e s s i s r o u t e d f r o m t h e hub down t o
t h e f l o o r p a n t h e n back t h r o u g h t h s c e n t r a l l o n g i t u d i n a l f r a a a
member.
As t h e h a r n e s s m x i t s thm r e a r o f t h e framm member,
m i g h t m i r a s emerge and t h e b a l a n c e i n t h e h a r n e s s arm r o u t e d
r i g h t a l o n g t h e c e n t r a l t r a n s v m r s e frame member.
I n the vic i n i t y o f thm g e n e r a t o r t h r e e m i r e s emerge.
I n t h e a r e a of
t h a v o l t a g e r e g u l a t o r , t h r e e more m i r e s emerge.
When t h a h a r n e s s r e a c h a s t h e o u t s i d e f r a m e - r a i l , i t i s r o u t e d back a l o n g
i t . A t thm d r i v a - t r a i n c e n t r a l s u p p o r t t w o w i r e s arm r o u t m d
l e f t and damn t o t h e r e v e r s e - l i g h t s n i t c h .
A t the brakm-light
s w i t c h two m i r e s e x i t t h e harneas.
From t h e b r a k e - l i g h t
s w i t c h thm h a r n e s s c o n t i n u a s back and down t h e r i g h t , r e a r
hanger f o r t h e r e a r body s e c t i o n .
A t t h m end o f t h e hanger
t h e harness t e r m i n a t a s s i x w i r e s i n a connector..
R e f e r r i n g t o thm numbmrs s h o r n i n F i g u r e 23,
h a r n e s s t e r m i n a t e as f o l l o w s
i n thm h u b - t o - r e a r
1.
2.
Connector
Connector
--
--
the mires
t a i l l i g h t pomar ( 1 6 ) * ~ * *
b r a k e l i g h t powmr ( 1 6 ) 8
-9
* numbers
** F r f r o n
i n p a r e n t h e s e s r m f m r t o rmcommended w i r e s i z e
hub, T - t o hub, Asahead i n h a r n a r r (away f r o m hub),
B=back i n h a r n e s s ( t o r a r d s hub)
9/
PlOllMTING THE ELECTRICAL COPlPONENTS
3.
4.
5.
6.
---
- CONTINLIED
r i g h t - t u r n i n d i c a t o r power ( 1 6 ) F
l e f t - t u r n i n d i c a t o r power ( 1 6 ) F
back-up l i g h t power ( 1 6 ) B
ground ( a s h o r t w i r e f r o m t h e connector t o a hinge-adjusting b e l t )
(- 1 6 )Brake-light pressure s w i t c h
b r a k e l i g h t power
(16) A
Brake-light pressure switch
+12 v o l t s , fused
(16) B
Reverse-light switch
back-up l i g h t power ( 1 6 )
Connactor
Connector
Connector
Connector
---
---
---
A
Reverse-light switch
+12 v o l t s , f u s e d ( 1 0 ) F
(16) A
B a t t e r y ( + ) t e r m i n a l and v o l t a g e r e g u l a t o r "BAT."
terminal
charging c u r r e n t (10)
V o l t a g e r e g u l a t o r I1ARm. l1t e r m i n a l
charging
c u r r e n t f r o m ammeter ( 1 0 ) F
V o l t a g e r e g u l a t o r llFIELDn t e r m i n a l
generator
f i e l d c o n t r o l (16) B
Generator armature
c h a r g i n g c u r r e n t t o ammeter (10) T
Generator f i e l d
generator f i e l d c o n t r o l (16)
--
--
--
--
-s o l e n o i d -A
Startar
+12 v o l t s from i g n i t i o n k e y
(16) F
O i l t e m p e r a t u r e sender
s i g n a l t o gau e ( 1 6 ) T
O i l p r e s s u r e sender
s i g n a l t o gauge q l 6 ) T
--
--
Water t e m p e r a t u r e sender
T
20.
21.
22.
23.
24.
Ignition c o i l (+)
from
Tach s i g n a l ( f r o m
(16) T
Spare
Courtesy l i g h t
Courtesy l i g h t
--
---
-- s i g n a l t o gauge
(16)
--
o r lfSW.ll
terminal
+12 v o l t s
i g n i t i o n key (16) F
sender o r c o i l )
(16) T
--
+12 v o l t s from s w i t c h e s
12 v o l t r e t u r n ( g r o u n d )
--
A g a i n r e f e r r i n g t o F i g u r e 23
t h e hub-to-front harness
i s r o u t e d from t h e hub up t o t h e cowl.
Then t o t h e l e f t unTwo
der t h e cowl t o e x i t t h e c o c k p i t through t h e f i r e w a l l .
l e a d s a r e r o u t e d back t o t h e l e f t - h a n d door c o u r t e s y l i g h t
s w i t c h ; t h e b a l a n c e a r e r o u t e d f o r w a r d a t o p t h e s i d e framer a i l t o t h e r a d i a t o r frame.
Three l e a d s emerge from t h e h a r ness i n t h e v i c i n i t y o f t h e dimmer s w i t c h and f o u r emerge a t
the horn relay.
V A L K Y R I E WIRING
HAR-NTSS AHRRNCtrnLNT
9/
mOUNTING THE ELECTRICAL COMPONENTS
-
CONTINUED
A t t h o r a d i a t o r frame, o u t s i d e t h e s p l a s h p a n e l , f i v e
l e a d s a r e b r o u g h t o u t o f t h e h a r n e s s t o t h e p a r k i n g and headlights.
The h a r n e s s i s t h e n r o u t e d r i g h t , t h r o u g h t h e s p l a s h
p a n e l , o v e r t h e t o p o f t h e r a d i a t o r frame, and t h r o u g h t h e
r i g h t splash panel.
J u s t i n s i d e t h e l e f t splash panel a s i n g l e l e a d t o t h e h o r n emerges and a n o t h e r l e a d i s b r o u g h t o u t
a t t h e c e n t e r o f t h e r a d i a t o r frame.
Just outside the r i g h t
s p l a s h p a n e l f i v e l e a d s e x i t t h e h a r n e s s t o t h e p a r k i n g and
headlights.
From t h e r i g h t s i d e o f t h e r a d i a t o r frame, t h e h a r n e s s i s
r o u t e d back a l o n g t h e s i d e f r a m e - r a i l t o t h e r i g h t - h a n d door
hinge sockets.
Near t h e f r o n t o f t h e f r a m e - r a i l a s i n g l e l e a d
i s b r o u g h t o u t , i f r e q u i r e d , f o r t h e e l e c t r i c f u e l pump.
Near
t h e h i n g e s o c k e t s t h r e e l e a d s e x i t f o r t h e w i n d s h i e l d w i p e r motor.
Two l e a d s e x t e n d i n t o t h e h i n g e a r e a t o t h e r i g h t - h a n d
door c o u r t e s y l i g h t s w i t c h .
I n t e r m s of t h e numbers shown i n F i g u r e 23, t h e c i r c u i t s
c a r r i e d i n t h e hub-to-front harness are,
courtesy
Courtesy l i g h t s w i t c h ( l e f t door)
l i g h t power ( 1 6 ) T
Courtesy l i g h t s w i t c h ( l e f t door)
+12 v o l t s ,
fused (16) F
H e a d l i g h t dimmer s w i t c h
+12 v o l t s f r o m h e a d l i g h t
s w i t c h (10)F
H e a d l i g h t dimmer s u i t c h
low-beam power ( 1 0 ) A
H e a d l i g h t dimmer s w i t c h
high-beam power ( 1 0 ) A
F u e l - l e v e l sender
s i g n a l t o gauge ( 1 6 ) T
Horn r e l a y t t s i g n a l N t e r m i n a l
s i g n a l from horn
b u t t o n (16) F
+12 v o l t s ( 1 6 ) F
Horn r e l a y " h o t w t e r m i n a l
power t o h o r n
H o r n r e l a y ~ c o n t r o l vt e r m i n a l
(16) A
Lamps g r o u n d
(10) F (10) A
H e a d l i g h t high-beam
high-beam power f r o m dimmer
s w i t c h (10) 0 (16) A
H e a d l i g h t low-beam
low-beam power Prom dimmer
smitch (10) 8 (16) A
L e f t - t u r n i n d i c a t o r lamp
v f l a s h e r t l s i g n a l (16) F
P a r k i n g lamp
+12 v o l t s f r o m h e a d l i g h t s w i t c h
(16) F (16) A
Horn
t t c o n t r o l " s i g n a l from horn r e l a y (16) B
+12 v o l t s , s w i t c h e d , f u s e d
Cooling f a n motor
(16) F
---
--
--
---
--
--
--
---
--
--
--
--
--
9/
flOUNTING THE ELECTRICAL COPlPONENTS
41.
42.
-
CONTINUED
--
+12 v o l t s f r o m h e a d l i g h t s w i t c h
(16)
R i g h t - t u r n i n d i c a t o r lamp
"flasher" s i g n a l ( 1 6 )
F
H e a d l i g h t low-beam
low-beam power f r o m dimmer
s w i t c h (16) 0
H e a d l i g h t high-beam
high-beam power from dimmer
s w i t c h (16) 8
Lamps g r o u n d
(10) 0 (16) A
E l e c t r i c f u e l pump
+12 v o l t s , s w i t c h e d , f u s e d
(16) F
W i n d s h i e l d w i p e r m o t o r ground
12 v o l t r e t u r n ( 1 6 )
B
Windshield u i p e r motor "runu t e r m i n a l
+12 v o l t s ,
fused (16) F
Windshield wiper motor " s t a r t " t e r m i n a l
12 v o l t
ground, s w i t c h e d ( 1 6 ) f
Courtesy l i g h t s w i t c h r i h t door)
courtesy l i g h t
power 1167 T
Courtesy l i b h t s w i t c h r i g h t door)
+12 v o l t s , f u s ed ( 1 6 ) f
P a r k i n g lamp
--
--
--
--
--
--
--
49.
SO.
51.
--
---
The f a c t o r y hub w i r i n g i n c l u d e s a s i x - f u s e f u s e - b l o c k w i t h
i n t e g r a l flasher m r n indicator interrupter) unit.
A Corvair
fuse-block, o r equivalent, i s appropriate.
The f u s e - b l o c k i s
mounted on t h e f i r e m a l l , a t i t s c e n t e r , a b o u t 10 i n c h e s above
the floor.
The f u s a s arm used f o r :
..
..
5.
6.
Headlights
Parking/courtesy/instrum~nt l i g h t s
~rake/back-up l i g h t s
W i n d s h i e l d w i p e r motor, c o o l i n g f a n
m o t o r and f u e l pump
Spare f o r a c c e s s o r i e s
Flasher u n i t
Hub w i r i n g i n c l u d e s t h e f o l l o w i n g (#16 w i r e u n l e s s o t h e r wise noted):
1.
2.
3.
Wire a l l g a u g e / i n s t r u m e n t grounds t o g e t h e r and t o
ground
Wire a l l g a u g e / i n s t r u m e n t l i g h t s t o g e t h e r and t o
vdimmeru t e r m i n a l on h e a d l i g h t s w i t c h
W i r e gauge " i g n i t i o n " t e r m i n a l s t o g e t h e r and t o
m a c c e s s o r y " t e r m i n a l on i g n i t i o n s w i t c h
9/
MOUNTING THE ELECTRICAL COmPONENTS
4.
5.
6.
-
CONTINUED
Wire ammeter 1 8 c h a r g i n g n ( + ) t e r m i n a l t o ,
Lead #14 ( s e e F i g u r e 23)
"BAT."
t e r m i n a l on i g n i t i o n s w i t c h
" B A T . 1" t e r m i n a l on h e a d l i g h t s w i t c h
c)
t h r o u g h f u s e #1
(d)
"BAT, 2" t e r m i n a l on h e a d l i g h t s w i t c h
t h r o u g h f u s e #2
(9) Lead #10 t h r o u g h fuse #S
Wire ammeter " d i s c h a r g i n g " ( - ) t e r m i n a l t o l e a d
#12
Wire i g n i t i o n s w i t c h N a c c e s s o r y n t e r m i n a l t o
F u e l pump
W i n d s h i e l d w i p e r m o t o r and c o o l i n g f a n s w i t c h
t h r o u h f u s e #4
Fusa 35
F l a s h e r t h r o u g h Cuss #b
18
{
The r e m a i n i n g hub w i r i n g i s f a i r l y o b v i o u s ; s . g . , t h e s t a r t e r s o l e n o i d i s w i r e d t o t h e " S O L . " t e r m i n a l on t h e i g n i t i o n s w i t c h ,
t e r m i n a l on t h e i g n i t i o n
t h e i g n i t i o n c o i l i s r i r e d t o t h e "IGN."
s w i t c h , t h e h e a d l i g h t dimmer s w i t c h i s c o n n e c t e d t o t h e h e a d l i g h t
switch, etc.
To c e n p l e t e t h e w i r i n g , t h e r e a r body s e t c t i o n i s r i r e d as an
independent u n i t .
The t a i l l i g h t , b r a k e l i g h t , back-up l i g h t and
turn-indicator(s) l i g h t wires are routed t o tha r i g h t s i d e hinge
and t e r m i n a t e d i n a c o n n e c t o r t o mate w i t h t h e h u b - t o - r e a r h a r n e s s
( l e a d s 1-6).
I f a l i c e n s e p l a t e l i g h t i s i n c o r p o r a t e d , i t s power
i s d e r i v e d from t h e t a i l l i g h t c i r c u i t .
10/
INSTALLING THE WINDOWS AND DOORS
Your V a l k y r i e k i t i n c l u d e s t h e f r o n t w i n d s h i e l d , t h e r e a r
wlndoiu and two d o o r s w i t h i n n e r p a n e l s .
This section describes
the i n s t a l l a t i o n o f these items.
The V a l k y r i e i s d e s i g n e d s p e c i f i c a l i y t o use t h e C h e v r o l e t
C o r v a i r , passenger c a r , w i n d s h i e l d and s u r r o u n d i n g chromm t r i m
( t h e t r i m i s a v a i l a b l e from your l o c a l Chevrolet d e a l e r
use t h e
p a r t s numbers g i v e n i n t h e p a r t s l i s t appended t o t h e s e i n s t r u c tions).
The r e a r window o p e n i n g o f t h e V a l k y r i e i , s d e s i g n e d t o
a c c e p t t h e F o r d mustang "t'astback" r e a r window, r e a r window r u b b e r
m o l d i n g and chrome s u r r o u n d i n g t r i m ( t h e t r i m and r u b b o r m o l d i n g
again using the
may be purchased f r o m y o u r l o c a l F o r d d e a l e r
p a r t s numbers i n t h e appended p a r t s l i s t ) .
--
--
The w i n d s h i e l d i s i n s t a l l e d u s i n s i l i c o n e r u b b e r s e a l a n t
The l i p of t h e w i n d s h i e l d
( s e e Chapter 2 f ~ o n s t r u c t i o n m a t e r i a l s
o p e n i n g i s f i l l e d w i t h s e a l a n t and t h e w i n d s h i e l d g l a s s i s immedia t e l y pressed i n t o place.
Next, t h e chromm t r i m i s p r e s s e d i n t o
p l a c e a r o u n d t h e o l a s s and t h e excess s e a l a n t i s wiped awav b e f o r e
Do n o t d i s t u r b t h e q l a s s f o r a t l e a s t m i g h t
i t commences t o s e t .
hours aftmr i n s t a l l a t i o n .
!'.
The r e a r window i s i n s t a l l e d b y f i r s t p l a c i n g t h e r u b b e r moldi n g around t h e g l a s s and t h e n p l a c i n g a t a l c - c o v e r e d ( f o r s l i p p e r i n e s s ) 1/8" c o r d ( v e n e t i a n b l i n d c o r d i s t y p i c a l ) i n t h e g r o o v e a( I f chrome t r i a i s used, t h e
r o u n d t h e o u t s i d s ot' t h e m o l d i n g .
t r i m - r e t a i n i n g c l i p s s h o u l d be screwed i n p l a c e a r o u n d thm window
opmning b e f o r e t h e g l a s s i s i n s t a l l e d .
S m a l l wood screws w i l l s u f f i c e t o hold the r e t a i n e r s securely),
Then t h e window i s p u t i n p o s i t i o n i n t h e window o p e n i n g as
Now, r i t h t h e window b e i n g pushshown i n F i g u r e 2 4 ( D r a w i n g A ) .
ed f i r m l y i n t o t h e opening, a p e r s o n i n t h e c a r w i t h d r a w s t h s c o r d
F i g u r e 24 ( D r a w i n g 0 )
f r o m t h e g r o o v e by p u l l i n g p e r p e n d i c u l a r l v t o t h e windshield surface.
As t h e c o r d i s ~ u l l e do u t o f
t h e groove, f u l l y removed, t h e m o l d i n g s h o u l d c o m p l e t e l y eggage
t h e l i p as i l l u s t r a t e d i n F i g u r e 2 4 ( ~ r a w i n gC ) .
After the rear
window i s i n s t a l l e d , t h e chrome t r i m can b s snapped i n t o i t s r e tainers,
--
--
S i d e windows may be as . e l a b o r a t e as y o u d e s i r e .
The most
s i m p l e window would be a p i e c e of P l e x i g l a s ( c l e a r p l a s t i c ) p e r m a n e n t l y a f f i x e d abovs t h e door and s e a l i n g a g a i n s t foam r u b b e r
w e a t h e r s t r i p p i n g when t h e door i s c l o s e d .
We have s u c c e s s f u l l y i n s t a l l e d F o r d LTD (1966 &door h a r d t o p
---front
window) c u r v e d g l a s s r o l l - u p windows, u s i n g a Mustang
v e n t window and window g u i d e s .
T h i s i n s t a l l a t i o n wakes an e l e g a n t
s i d e window arrangement b u t r e q u i r e s c o n s i d e r a b l e i n g e n u i t y on
t n e p a r t o f t h e b u i l d e r t o make i t s m o o t h l y o p e r a b l e .
A s i d e window k i t i s a v a i l a b l e from F i b e r f a b w h i c h use9
a f i x e d v e n t window and a s t o c k r o l l - u p mechanism w h i c h can
be o b t a i n e d from a used c a r wrecker.
10/
INSTALLING THE WINDOWS AND DOORS
-
CONTINUED
Rear Window I n s t a l l a t i o n
A
CU)ss
[r'.',.
,c/u#FJa=L&=S
'.
C
.
The s t e p s t o be t a k e n t o i n s t a l l t h e V a l k y r i e d o o r s a r e :
1. A t t a c h t h e h i n g e s t o t h e d o o r s as shown i n F i g u r e 25.
Do n o t t i g h t e n .
2.
Cut o u t t h e h i n g e s o c k e t o p e n i n g s as shown i n F i g u r e
26.
The o u t l i n e o f t h e c u t - o u t i s i m p r i n t e d i n t h e
door jamb as a g u i d e f o r c u t t i n g .
3. P o s i t i o n t h e d o o r s i n t h e d o o r openings.
Clamp tsmporarily.
4.
A t t a c h t h e h i n q e s t o t h e h i n g- e s o c k e t s i n thm body
use shim, ifr e q u i r e d .
5.
Secure a l l b o l t s
i n t h s d o o r and i n t h e h i n g e
sockets
and r e l e a s e t h e clamps.
--
--
--
The h i n g e s t h a t a r e used on t h e V a l k y r i e d o o r s a r e obt a i n e d f r o m y o u r l o c a l F o r d d e a l e r ( o r a w r e c k i n g y a r d ) as
1965 F o r d passenger c a r , f r o n t - d o o r h i n g e s ( s e e t h e appended
parts l i s t for details).
N o t e i n F i g u r e 25 t h a t t h e V a l k y r i e
use9 t h e F o r d r i h t - h a n d h i n g e s on t h e l e f t door and v i c e - v e r e a .
A l s o t h e top F o r
a r e mounted a t t h e b o t t o m o f t h e V a l k y r i e doors.
10/
I N S T A L L I N G THE WINDOWS AND DOORS
-
CONTINUED
We h a v e f o u n d a t t h e f a c t o r y t h a t d o o r m o u n t i n g o p e r a t i o n s
a r e e x p e d i t e d c o n s i d e r a b l y b y u s i n g n u t - p l a t e s and "horseshoe
shims" ( s e e F i g u r e 2 7 ) i n t h m h i n g e s o c k e t s .
four nut-plates
p e r d o o r a r e required a l o n g u i t h a n a s s o r t m e n t o f s h i m s ( a dozThe n u t - p l a t e s a r e
en o f each t h i c k n e s s s h o u l d be s u f f i c i e n t ) .
i n s t a l l e d on t h e i n e i d e of t h e h i n g e s o c k e t s , i n t h e same manner
as n u t s b u t d o n o t r e q u i r e a wrench f o r t i g h t e n i n g .
Once t h e
h i n g e m o u n t i n g b o l t s are engaged i n t h e n u t - p l a t e s , a l l s h i m ming, f i t t i n g and t i g h t e n i n g of' b o l t s i n t h e h i n g e s o c k e t s can
be a c c o m p l i s h e d b y one p e r s o n w o r k i n g i n t h e m h e e l a e l l .
FIGURE 25
F I G U R E 26
material:
1/4" s t e e l
1 1D r i l l a n d
NUT PLATE
HORSESHOE S H I M
material:
1/32" aluminum
1/16" aluminum
1/8" a l u m 1num
F I G U R E 27
11/
FINISHING THE INTERIOR
--
UPHOLSTERY
The u p h o l s t e r i n g of y o u r V a l k y r i e i s p u r e l y a m a t t e r of
You c a n b e a s a u s t e r e o r a s e l a b o r a t e a s y o u
personal taste.
p u r e l y f u n c t i o n a l f o r t h e "road machine" buff or posh
desire
f o r t h e grand touring enthusiast.
--
A t t h e f a c t o r y , we u s e , o f c o u r s e , t h e V a l k y r i e 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 t e x t r a c o s t ) .
Thm u p h o l s t e r y k i t
c o n s i s t s of a u t o m o t i v e - g r a d e c a r p e t c u t t o f i t t h e f i r e w a l l ,
f l o o r , and h e a d l i n e r a r e a s .
he c a r p e t i s b o u n d w i t h 1-1/2"
wide c a r p e t - b i n d i n g t o p r e v e n t f r a y i n g .
The h e a d l i n e r c a r p e t
i s e x t e n d e d down t h e w i n d s h i e l d p i l l a r s .
Also i n t h e k i t are
t h e v i n y l door p a n e l s , custom v i n y l " s l i n g w seats and a q u a r t
of " f a a t t a c k " trim a d h e s i v e .
I f y o u h a v e access t o a commercial, h e a v y - d u t y s e w i n g m a c h i n e
The materials
y o u c a n make y o u r o u n c a r p e t i n g a n d i n t s r i o r t r i m .
r e q u i r e d are:
1.
2.
3.
4.
5.
6.
7.
8.
4 y a r d s v i n y l (54" wide)
1 0 y a r d s c a r p e t (36" w i d e )
2 yards carpet-jute f o r padding under floor carpet
5 0 y a r d s , 1-1/2" w i d e c a r p e t b i n d i n g
2 s h e e t s , 3' x 4 ' . w a t s r p r o o f p a n e l b o a r d a p p r o x i m a t e l y 1/8" t h i c k .
1 q u a r t trim a d h e s i v e
"fast tackw variety
2 0 , g r o m m e t - h e a d trim screws a n d b e z e l s
8 ' c a n v a s (34" w i d e )
--
Use h e a v y p a p e r t o m a k e p a t t e r n s o f t h e i n t m r i o r s u r f a c e s
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 (make s u r e it
i s n o t upside-down) and c u t .
S e r on t h e binding.
T h e same
"paper-patternntechnique is u s e d t o d e v e l o p t h e d o o r p a n m l s
which are c o n s t r u c t e d o f v i n y l sewn t o p a n e l - b o a r d
a ncustoni z i n g n e f f e c t c a n b e g a i n e d b y s a n d w i c h i n g u p t o 1" foam r u b b e r s h e e t i n g betwemn t h e v i n y l a n d t h e p a n e l - b o a r d a n d t h e n
s t i t c h i n g a design i n t h e vinyl.
of t h e car.
--
--
--
Before i n s t a l l i n g t h e carpets
especially the headliner
r o u g h - u p 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 c o v e r e d w i t h a n y coarsa
sand paper.
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 ner or acetone.
I f t h e s u r f a c e s are n o t p r e p a r e d , t h e c a r p e t
may n o t p r o p e r l y a d h e r e , p a r t i c u l a r l y t h e h e a d l i n e r c a r p e t .
When t h e s u r f a c e s a r e r e a d y , c o a t t h e m t h i c k l y w i t h a d hesive
also c o a t t h e back s i d e of t h e c a r p e t ( o r j u t e padding
f o r t h e f l o o r ) . 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 t h e c a r p e t .
Wood b l o c k s a r e g l u e d i n t o t h e w i n d s h i e l d p i l l a r s t o p r o v i d e a
mounting s u r f a c e f o r t h e c a r p e t i n t h a t a r e a .
Door p a n e l s are
--
11/
FINISHING THE INTERIOR
-
UPHOLSTERY
g l u e d i n p l a c e , o r p r e f e r a b l y , a t t a c h e d w i t h chrome-plated,
grommet-head r o o d s c r e w s b a c k e d w i t h c h r o m e - p l a t e d b e z e l s .
The V a l k y r i e s e a t s a r a m o l d e d i n t o t h e f i b e r g l a s s f l o o r pan.
I f t h e s e a t p o s i t i o n i s e x a c t l y r i g h t f o r you, t h e s e a t s
need o n l y be c o v e r e d u ~ i t ha v i n y l - o v e r - f o a m r u b b e r p a d t o be
completed.
I f , hoaewer, t h e s e a t i n g p o s i t i o n needs t o be adj u a t e d f o r w a r d and/or u p " s l i n g n s e a t s s h o u l d be e m p l o y e d a s
i n t h e f a c t o r y - b u i l t cars.
F i g u r e 28 shows t h e m e t h o d t o be
The s l i n g i s
used t o i n s t a l l t h e s e a t s u p p o r t s o r
made w i t h l o o p s a t e i t h e r end as shown i n t h e f i g u r e .
metal
s t r i p s a r e i n s e r t e d Fn t h e l o o p s and t h e s l i n g i s s e c u r e d t o
t h e f i b e r g l a s s b y t r i m s c r e w s p a s s e d t h r o u g h t h e c s n v a e and
The v i n y l - o v e r - f o a m r u b b e r
metal s t r i p s i n t o t h s floorpan.
s e a t c u s h i o n can be e i t h e r l a i d i n t h e c a n v a s s l i n g o r sewn
d i r e c t l y t o i t t o prevent i t from s l i d i n g .
Other i t e m s t o be 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 a s h t r a y s mounted i n t h e c o n s o l e , i n t e r i o r l i g h t mounted
The c o n s o l e s u r f a c e may be c o v e r e d
between t h e s e a t s , e t c .
w i t h adhesive-backed p l a s t i c sheet i m p r i n t e d w i t h a wood-grain
( a v a i l a b l e f r o m 3fl a n d o t h e r - a n u f a c t u r e r s ) .
The d a s h may b e
Etc,
Etc.
L e t your imaginetion
padded and v i n y l - c o v e r e d .
be y o u r g u i d e !
F I G U R E 28
12/
FINISHING THE EXTERIOR
--
PAINTING
The m o s t i m p o r t a n t i t e m i n t h e a r e a of e x t e r i o r f i n i s h
i s , o f course, t h e p a i n t i n g .
The " f i r s t i m p r e s s i o n w o t h e r s
w i l l have o f y o u r V a l k y r i e i s d e p e n d e n t on t h e q u a l i t y o f t h e
painting.
Fortunately, i t i s possible t o achieve a b e a u t i f u l
no e l a b o r a t e bakse x t e r i o r f i n i s h u s i n g o n l y a s p r a y gun
ovens, e t c . a r e r e q u i r e d .
--
F i b e r g l a c ~ si s v e r y c o m p a t i b l e w i t h a c r y l i c l a c q u s r s ,
Lacquers, a l s o , a r e t h e e a s i e s t and most t r o u b l e - f r e e f i n i s h e s
t o apply.
They c a n e v e n be a p p l i e d i n a s l i g h t l y d u s t y ent h e d u s t and a n y s p r a y i n g i m p e r f e c t i o n s c a n be
vironment
subsequently rubbed out.
J u s t f o l l o w t h e i n s t r u c t i o n s which
s p r a y where t h e r e i s p l e n t y o f venaccompany t h e l a c q u e r
t i l a t i o n and d o n ' t a t t e m p t s p r a y i n g o n c o l d a n d / o r damp days.
--
--
--
most f i b e r g l a s s b o d i e s
About body s u r f a c e p r e p a r a t i o n
have s l i g h t i m p e r f e c t i o n s s u c h as p i n h o l e s o r marks made b y
mold p a r t i n g l i n e s .
O f t e n a f e w s c r a t c h e s w i l l be added d u r i n g shipment.
Body p u t t y (eg,, " G r e e n S t u f f " ) and f i n e sand
p a p e r s h o u l d t a k e c a r e o f a n y body s u r f a c e i m p e r f e c t i o n s y o u
m i g h t encounter.
We a r e p r o u d o f t h e s u r f a c e f i n i s h o f o u r b o d i e s .
We u s e
s p e c i a l c a r e i n p r e p a r i n g m o l d s u r f a c e s and s p e c i a l m a t e r i a l s
a r o u n d body edges t o m i n i m i z e c h i p p i n g .
One o f o u r own A z t e c s ,
w h i c h has t r a v e l l e d o v e r 50,000 m i l e s i n a l l t y p e s o f w e a t h e r
and o v e r a l l t y p e s o f r o a d s , does n o t have one body c r a c k .
It
s t i l l r e t a i n s i t s o r i g i n a l p a i n t , too!
Your V a l k y r i e k i t b o d y w i l l h a v e a c o l o r when y o u r e c e i v e
i t . I n most i n s t a n c e s , t h i s c o l o r w i l l be b l a c k .
This i s not
I t i s a s p e c i a l G e l - C o a t f i n i s h y o u r body
tho finished color.
has been g i v e n t o a c h i e v e t h s b e s t p o s s i b l e s u r f a c e .
B e f o r e y o u p a i n t y o u r V a l k y r i e , t h e e n t i r e body s h o u l d be
li h t l sanded u i t h #400 s a n d p a p e r ( p r e f e r a b l y wet-sanded).
e s a n d i n g i s done i n o r d e r t o " s c u f f up" t h e s u r f a c e w h i c h i s
o t h e r w i s e t o o s l i c k t o a l l o w t h e p a i n t t o p r o p e r l y adhere.
Remember t o sand l i g h t l y
you a r e s c u f f i n g t h e surface, n o t
r e - s t y l i n g t h e body!
w
--
F o l l o w i n g t h e s a n d i n g , t h e body s h o u l d b e washed c f f and
m i p e d w i t h P r e p s o l o r some o t h e r p a i n t p r e p a r a t i o n l i q u i d t o
e l i m i n a t e any l i n g e r i n g d u s t , o i l o r d i r t ( b e p a r t i c u l s r l y
c a r e f u l t o remove o i l s f r o m f i n g e r p r i n t s , e t c . , a s t h e s e o i l y
s p o t s w i l l produce " f i s h e y e s " i n t h e f i n i s h ) .
The b o d y i s
now r e a d y f o r p r i m e r and p a i n t .
12/
FINISHING THE EXTERIOR
-
CONTINUED
Other i t e m s o f e x t e r i o r f i n i s h a r e :
TAIL SECTION LATCHES.
llle use, o n ' t h e f a c t o r y - b u i l t c a r s ,
Two a r e r e q u i r e d
F o r d F a l c o n o r Mustang hood l a t c h e s .
one on each s i d e o f t h e c a r .
The l a t c h i s mounted j u s t
ahead o f t h e r u b b e r bumper cup i n t h e h o r i z o n t a l s u r f a c e
i n t e r s e c t i n g t h e r e a r wheel opening,
Ths l a t c h s t u d i s
mounted i n t h e t a i l s e c t i o n .
The o p e r a t i n g arms must be
s h o r t e n e d t o c l e a r t h e i n n e r s u r f a c e o f t h e body and t h e
s a f e t y c a t c h s h o u l d be removed f r o m t h e l a t c h used on t h e
passenger's s i d e o f t h e car.
--
Many o t h e r l a t c h e s a r e s u i t a b l e .
F o r example, t h e k e y o p e r a t e d v a r i r t y used as hood l a t c h e s f o r mG-TF, e t c . ,
o f f e r a measure o f s e c u r i t y as w e l l as h o l d i n g down t h e
t a i l section.
2.
DOOR LATCHES.
Any c o n v e n t i o n a l d o o r l a t c h can be used
such as mustang, C o r v e t t e , e t c .
3.
HEADLIGHT COVERS.
These can be made f r o m 3/16" P l e x i g l a s
Covers
b y h e a t i n g and f o r m i n g o v e r an a p p r o p r i a t e mold.
are also a v a i l a b l e from F i b e r f a b a t e x t r a cost.
The c o v e r s
a r e i n s t a l l e d u s i n g s m a l l "L-shapedM t a b s a r o u n d t h e heJadl i g h t o p e n i n g t o w h i c h t h e c o v e r can be a t t a c h e d
five
t a b s p e r c o v e r s h o u l d be s u f f i c i e n t .
These t a b s can be
made o f s h e e t m e t a l s h o u l d you d e s i r e .
--
Be s u r e t o check w i t h y o u r l o c a l Department of m o t o r Veh i c l e s t o f i n d o u t whether t h e use o f h e a d l i g h t c o v e r s a t
n i g h t I s l e g a l i n your s t a t e .
-
4.
A I R SCOOPS
ENGINE A I R INTAKES.
The a i r scoops on t h e
s i d e o f t h e V a l k y r i e body can be made f u n c t i o n a l i f you
wish.
The upper d u c t s can be u t i l i z e d t o p r o v i d e f r e s h
a i r t o t h e cab a-la-mustang f a s t b a c k .
The l o w e r d u c t s
can b e used t o s u p p l y c o o l a i r t o t h e e n g i n e compartment
v i a f l e x i b l e ~hose (we have f o u n d l a u n d r y d r y e r vent-hose
t o be q u i t e s a t i s f a c t o r y f o r a i r d u c t i n g p u r p o s e s ) .
5.
IYIRRORS.
F o r t h e i n t e r i o r r e a r - v i e w m i r r o r , any m i r r o r
w h i c h mounts ( u s i n g epoxy g l u e ) t o t h e w i n d s h i e l d , s u c h
a8 T - B i r d can be used.
F o r s i d e m i r r o r s , t h e r e a r e any
number o f m i r r o r s w h i c h can be used.
The 1965 mustang
m i r r o r i s good.
THE FORD 289 "PROBLEM"
F i b o r f a b s t r o n g l y recommends t h e u s e o f t h e C h e v r o l e t
The k i t
was e n g i n e e r e d s p e c i f i c a l l y t o a c c e p t t h e s e e n g i n e s .
283-327 s e r i e s o f e n g i n e s w i t h t h e V a l k y ' r i e k i t .
However,some p e o p l e h a v e w i s h e d t o u s e t h e 221-289
s e r i e s o f Ford engines w i t h t h e V a l k y r i e k i t , e i t h e r o u t o f
a p e r s o n a l p r e f e r e n c e f o r F o r d p r o d u c t s o r because t h e y h a d
a Ford engine
o n hand.
The F o r d e n g i n e s a r e n o t a s e a s i l y u t i l i z e d u i t h t h a
V a l k y r i e k i t b u t , w i t h one e x c e p t i o n , t h e y can be u s e d ifa
" F o r d - t o - C h e v y n b e l l h o u s i n g i e used.
These s p e c i a l b e l l h o u s i n g s a r e a v a i l a b l e a t speed s h o p s
t h r o u g h o u t t h e c o u n t r y a n d Prom a u t o m o t i v e s p e c i a l t y o u t l e t s
b y m a i l s u c h as H o n e s t C h a r l e y ' s Spmed Shop i n C h a t t a n o o g a ,
Tennessee.
Ths b e l l h o u s i n g s t h e m s e l v e s a r e made b y t h e T r a n s Da t Company o f C a l i f o r n i a .
'The numbers g i v e n b e l o w a r e t h e
& % - [ ) a p t numbers.
The T r a n s - D a p t
Number f o r t h e TRANSFIISSION i s #25.
ENGINE SERIES:
Ford
2 2 1 t h r u 289 1962-1964
5 - B o l t H o u s i n g ( ~ o Tt & C T r a n s m i s s i o n )
USE TRANS-DAPT AF-900
$32.99
-------
Ford
260 t h r u 289 1965-1967
6-Bolt H o u s i n g ( N o t T & C T r a n s m i s s i o n )
USE TRANS-DAPT AH-922
$34.99
-------
Ford
289 1965-1967
6 - B o l t Housing ( T & C ~ i d e - B o l t )
TRANS-DAPT HAS NO BELLHOUSING AVAILABLE
THEREFORE THIS ENGINE I S
(PLATE ONLY)
NOT SUITABLE FOR VALKYRIE INSTALLAI I O N .
--
T h r o u g h o u t t h i s c o n s t r u c t i o n b o o k l e t , we have r e f e r r e d t o
p a r t s w h i c h c a n be used i n t h e c o m p l e t i o n of your V a l k y r i e .
Here i s a l i s t o f i t e m s w h i c h have been p r e v i o u s l y m e n t i o n ed i n t h e t e x t .
I n many i n s t a n c e s p a r t numbers a r e g i v e n t o a s s i s t you i n obt a i n i n g t h e i t e m s from a Ford o r Chevrolet dealer.
Remember
t h a t a p p r e c i a b l a s a v i n g s ( w i t h no s a c r i f i c e o f q u a l i t y ) can
be a c h i e v e d ifyou w i s h t o g e t t h e i t e m s f r o m a w r e c k i n g y a r d .
A l s o , t h e r e a r e many a l t e r n a t i v e t y p e s of p a r t s t h a t can be
used, p a r t i c u l a r l y f o r t a i l l i g h t s , e t c .
L e t your imaginat i o n ba y o u r g u i d e !
HARDWARE ITEm
MANUFACTURER
DESCRIPTION AND/OR
VIANUFACTURER'S PART #
>
TRANSMISSION GROUP-1965
Case
I n p u t ( c l u t c h ) gear
Side cover gasket
Needle b e a r i n g s ( 7 2 )
General motors
Chevrolet
Corvair
TRANSPlISSION GROUP-1966
-1967
Case
I n p u t ( c l u t c h ) gear
Side cover gasket
Needle bearings(72)
3874333
3859987
3858990
7451240
D i f f e r e n t i a l case -1965
3855502
-1966
D i f f e r e n t i a l case -1967
3873484
D i f f e r e n t i a l cover
gasket
a l l years
-
Bellhousin
typical
*
3899186
3851508
3775033
7451240
S
(aluminum,
6257706
General motors
Throw-out b e a r i n g g u i d e
(T89B-6)
Corvette
Gas t a n k (1960-1964)
Corvair
-
-
GM
Cm
3185564
3709331
3785035
DESCRIPTION AND/OR
MANUFACTURER'S PART
#
HARDWARE ITEM
MANURRCTORER
Vent u i n d o u assembly
F o r d M o t o r Co.
1965 Mustang wind-wing
S i d e windou g u i d e
assembly
F o r d m o t o r Co.
C5A2
S i d e window g l a s s
F o r d m o t o r Co.
1965 LTD 4-door h a r d t o p
f r o n t window g l a s s
Windmw l i f t mechanism
Chevrolet
1955 passenqsr c a r
Door l o c k c y l i n d e r s
F o r d m o t o r Co.
C50Z-6221984-A1
Door l a t c h e s
F o r d m o t o r Co.
Left
Right
T a i l s e c t i o n rubber
bumper
Chevrolet
3742247
T a i l section l a t c h
and s t u d
F o r d m o t o r Co.
C5ZZ-16700-A
CSZZ-16929-A
-
67222A57C
- - C4SZ-6323813-C
C4SZ-6321812-C
Door h i n g e s
RH t o p
RH bottom
LH t o p
LH b o t t o m
F o r d m o t o r Co.
H e a d l i g h t assembly
Chevrolet
897185
897186
Parking l i g h t s
Pontiac
Gran P r i x o r GTO
TAIL LIGHTS
RH o u t b o a r d
LH o u t b o a r d
RH i n b o a r d
LH i n b o a r d
General motors
Corvette
C5AZ-6222810-C
C5AZ-622280C-0
CSAZ-6222811-C
C5AZ-6222801-0
910554
910553
910558
910557
910427
910428
Back-up r i g h t
Back-up l e f t
I g n i t i o n switch
Chevrolet
Dimmer s w i t c h
Chetvrolet
Headlight switch
Chevrolet
Accessory s w i t c h e s
Lucas o r
micro-dot
m ANLIFACTURER
DESCRIPTICIN AND/OR
IYANUFA CTURER ' S PART #
Horn r e l a y
Chevrolet
D e l c o 920-12V
Horn
Chevr o l e t
9000517
Windshield r i p e r
assembly
Lucas
A w s t i n - H e a l e y , TR-3
XK-150, XK-140
Fuseblock
Chevrolet
Corvair,
1962 on
A i r o r heater ducts
EPlPI
"Empivent"
FRONT WINDOW TRIM
W i n d s h i e l d mldg.
Chevrolet
1965 C o r v a i r
HARDWARE ITEM
b
.r
Windshield c l i p s
REAR WINDOW TRIM
Rubber m o l d i n g
Trim s t r i p s
Rear t r i m c l i p s
( 2 0 - 2 4 needed)
Ford
1966 m u s t a n g
Chevrolet
4489204
4489203
4469665
4469664
4489205
4474354 ( 1 2 needed)
CSZZ-6342084A
C5ZZ-6342404A-right
C5ZZ-6342405A-left
CSZZ-6342430A-rt. u p p e r
CSZZ-6342431A-lt,
upper
C5ZZ-6342084A
1
FIBERFAB SERVICE POLICY
The F i b e r f a b P r o d u c t W a r r a n t y p r o v i d e s :or
the return
t o t h e f.actory o f d e f e c t i v e p a r t s f o r s u b s c q u e r t r e p a i r o r
r e p l a c e m e n t , f o r no c h a r g e .
The p u r c h a s e r [nay a l s o choost:
t o bring p a r t s , suspected of being d e f e c t i v e , t o t h z nearest
Flberf'ab D i s t r i b u t o r f o r I n s p e c t i o n and r ? p a i r l o r r e p l a c e r n e ~ t ,
i f s u c h r e p a l r o r r e p l a c e m e n t i s deemed j u s t 1 : ' i e d by s a i d
distributor.
Such r e p a i r o r r e p l a c e m e n t must be a u t h o r i z e d
by t h e f a c t o r y i n o r d e r f o r t h e d i s t r i b u t o r t o be r e i m b u r s e d
f o r t i m e and/or ma t e r i a 1 e x p e n d e d .
A u t h o r i z e d r e p l a c e m e n t w i l l be r e i m b u r s e d e i t h e r by
a c r e d i t t o t h e d i s t r i b u t o r l s a c c o u n t i n a r b amount e q u a l 20
t h e d i s t r i b u t o r l s c o s t f o r t h e p a r t r e p l a c e d o r by d l r e c replacement of the p a r t i n t o t h e d i s t r i ! u t o r '
charge.
s t o c k f o r no
A u t h o r i z e d r e p a i r w i l l be r e l m b u r s e d by a c r e d i t t o
t h e d i s t r i b u t o r ' s a c c o u n t i n a n amount e q u a l t o t h e : o s t - t o r e p a i r d e r i v e d a s t h e p r o d u c t o f t h e number o f h o u r ? t a r e p a i r
t i m e s a s h o p - r a t e n e g o t i a t e d between t h e c l i s t r i b u t o r a n d
Fiberfab p r l o r t o the repair.
I n any i n s t a n c e t h e c o s t - t o -
r e p a i r s h a l l not exceed f i f t y - p e r c e n t o f t h e value of t h e
part requiring repair.
FIBERFAB, A D i v i s i o n Of VELQCIDAD, I N C .
FIBERFAB PRODUCT WARRANTY
F i b e r f a b p r o d u c t s a r e guaranteed f o r a p e r i o d of s i x
months from t h e d a t e o£ t h e i r d e l i v e r y a g a i n s t d e f e c t i v e .
m a t e r i a l a n d / o r workmanship.
Fiberfab w i l l replace or r e p a i r
any p a r t ' r e t u r n e d t o cnr f a c t o r y , o r i n s p e c t e d i n t h e f i e l d b y
a n a u t h o r i z e d r e p r e s e n t a t i v e of F i b e r f a b , and upon examination
found t o be d e f e c t i v e .
h-ver,
Before any merchandise i s r e t u r n e d ,
t h e purchaser must o b t a i n w r i t t e n a u t h o r i z a t i o n
from t h e f a c t o r y .
Merchandise a r r i v i n g without t h i r
a u t h o r i z a t i o n w i l l iuxnediately be r e t u r n e d t o t h e purchaser
a t t h e p u r c h a s e r ' s expense.
In addition, transportation
chargor f o r p a r t s r e t u r n e d under t h i s warranty w i l l be b c n e
by t h e p u r c h a s e r i f t h e r e t u r n e d p a r t proves t o k not
defective.
Other equipment a n d / o r a c c e s s o r i e s , not manufactured
b y F i b e r f a b b u t f u r n i s h e d w i t h F i b e r f a b p a r t s s h a l l be
r u b j e c t t o t h e g u a r a n t e e ar provided b y the manufacturer of
s a i d equipraant a n d / o r a c c e a s o r i e r
.
Except f o r t h i e w a r r a n t y , t h e r e a r e no other g u a r a n t e e s ,
w a r r a n t i a r o r r e p r e s e n t a t i o n 8 e x p r e s r e d o r implied.
No
person, f i r m , o r c o r p o r a t i o n i s a u t h o r i z e d t o aasunv f o r u r e
any o t h e r l i a b i l i t y i n ~ o n n e c t i o nw i t h t h e s a l e of our
product r
.
FIBERFAB, A D i v i s i o n of VELOCIDAD, I N .