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Table of Contents
TABLE OF CONTENTS ................................................................................................................................................................... I
FORWARD ..................................................................................................................................................................................IV
STATEMENT OF NON-LIABILITY .................................................................................................................................................VI
SAFETY TIPS .............................................................................................................................................................................VII
TOOLS AND SUPPLIES LIST .......................................................................................................................................................VIII
CHAPTER 1 - DONOR PARTS AND PARTS NEEDED...................................................................................................... 10
DONOR PART SELECTION TIPS .................................................................................................................................................. 11
DISASSEMBLY OF A MUSTANG DONOR FOR PARTS ...................................................................................................................14
DONOR PART PREPARATION ..................................................................................................................................................... 27
CLEANING AND DETAILING .......................................................................................................................................................35
NOT USING A DONOR ................................................................................................................................................................. 36
CHAPTER 2 - STEP BY STEP CHASSIS BUILD-UP .......................................................................................................... 38
UNPACKING YOUR REPLICA KIT ...............................................................................................................................................39
REMOVAL OF BODY & ALUMINUM ........................................................................................................................................... 39
ENGINE BAY ALUMINUM .......................................................................................................................................................... 41
FRONT SUSPENSION INSTALLATION .......................................................................................................................................... 43
STEERING SHAFT....................................................................................................................................................................... 50
STEERING RACK INSTALLATION................................................................................................................................................ 52
REAR-END ................................................................................................................................................................................ 55
SUSPENSION TORQUE SPECS CHART ......................................................................................................................................... 58
FUEL TANK AND FUEL FILTER................................................................................................................................................... 59
PEDALS ..................................................................................................................................................................................... 61
MASTER CYLINDER & PUSH ROD.............................................................................................................................................. 63
COCKPIT ALUMINUM ................................................................................................................................................................ 65
FUEL, BRAKE AND BATTERY LINES .......................................................................................................................................... 70
FUEL LINE................................................................................................................................................................................. 73
BATTERY RELOCATION KIT ...................................................................................................................................................... 75
ENGINE PREPARATION .............................................................................................................................................................. 77
ALTERNATE DRIVE PULLEY ...................................................................................................................................................... 78
ENGINE/TRANSMISSION/DRIVE SHAFT ...................................................................................................................................... 79
ACCELERATOR CABLE .............................................................................................................................................................. 83
CLUTCH CABLE......................................................................................................................................................................... 87
MASS AIR METER, FUEL VAPOR CANISTER .............................................................................................................................. 87
RADIATOR, HOSES & FAN SHROUD........................................................................................................................................... 88
WIRE HARNESS AND EEC-IV.................................................................................................................................................... 92
GAUGE POD INSTALLATION .................................................................................................................................................... 102
ALUMINUM TRUNK & SIDE WALLS......................................................................................................................................... 103
EMERGENCY BRAKE HANDLE AND CABLES ............................................................................................................................ 106
TRANSMISSION TOP COVER .................................................................................................................................................... 110
WHEELS, TIRES AND RIDE HEIGHT.......................................................................................................................................... 111
CHECKING THE RUNNING GEAR .............................................................................................................................................. 112
FOOT BOX TOP COVER............................................................................................................................................................ 113
ROLL BAR DRILLING............................................................................................................................................................... 114
BODY CUT-OUTS .................................................................................................................................................................... 115
HOOD PINS.............................................................................................................................................................................. 121
BODY MOUNTING ................................................................................................................................................................... 124
REAR QUICK JACK BUMPERS .................................................................................................................................................. 126
SIDE BODY MOUNTS ............................................................................................................................................................... 126
FRONT BODY MOUNTS............................................................................................................................................................ 127
FRONT QUICK JACK BUMPERS ................................................................................................................................................ 127
BODY PREP AND PAINTING...................................................................................................................................................... 128
RUBBER SEAL ON ALUMINUM................................................................................................................................................. 130
FINAL BODY MOUNTING ......................................................................................................................................................... 131
REAR COCKPIT CORNERS........................................................................................................................................................ 131
TRUNK HINGES ....................................................................................................................................................................... 133
TRUNK LATCH ........................................................................................................................................................................134
SIDE LOUVERS......................................................................................................................................................................... 135
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