Prior to stretching the frame, you will
need to loosen or remove the radiator hoses, unhook the shifting
cables, fuel line, brake line and the wires that are attached to the
firewall that do not have sufficient length to be moved back 11
inches. If you have not removed the battery, you will need to do so at
this point. The cut will actually go through the current location of
the battery. |
Preparation for cutting
It is very important that you have a level surface to work on for this
next step. Place the car on blocks and use shims to level the car
across the front as well as along the door frames. Be sure to support
the front half of the car in such a manner that when you finish the
cuts that the front will still be supported. Use masking tape or duct
tape to mark the frame 5 inches back from the firewall where you plan
to cut. This works better than trying to draw a scribed line on the
frame.
You will cut the cradle at a location 1.5 inches back from the point
where it attaches to the section next to the firewall.
Once the car is fully supported, place a floor jack under the back
half of the car beneath the support that runs under the engine. Cut
through the first two frame pieces on each side. Then cut through
the cradle section. Once the car is sectioned move the back half away
using the floor jack. Insert the 11 inch spacers starting on the top
rail.
Tack weld the extension brackets in place. Continue to check the level
both across the car as well lengthwise. |
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Check
for square by using diagonal measurements. A good measurement is from
the edge of the rear strut support to where the firewall meets the
frame.
Measuring to check for square
When you are done welding the 2” square tube, you will then weld the
flat bar on the opposite side to provide additional structural
support. |
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I have had multiple questions about the
rack that was built to lift the car. It consists of 2 - 2x8x16ft for
the top rail. These were fastened to 4x4x7'6" posts with casters on
the bottom. I used 2x8x7ft across the front and back on the top and
bottom. I used 2x4 angle braces from the post to the 2x8s. I placed a
2x8 above the wheel wells over both the front and the rear wheels. I
installed pulleys in the 2x8s over the wheel wells. I used a come
along attached to the ropes that allow me to lift the front and back
together or separately. You do need to make sure that your garage has
the clearance to move past the garage door opener as well as allow the
doors to close. I have about 1/2" clearance from the opener and about
2" from the door. It's tight but I can do it without any assistance. |
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In order for the firewall to match up to
the rear window on the roadster, it is necessary to move the firewall
forward 3". This is accomplished by cutting on either side next to
the frame and simply puling the firewall forward. This is not
necessary on the VT or SE. To anchor the firewall I used 1x2 tube that
I welded on top of the frame. I then welded a small section
perpendicular to the firewall and welded this to a piece fastened to
the top of the firewall. Because the firewall metal is very thin and I
welded flanges on either side of the 1x2 to straddle the firewall for
additional support. |
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The
front hinges will rest on a bracket that is fabricated from 1x3 inch
tube with a piece of 3/8 inch flat bar welded to the top. This piece
is challenging to get welded in place. It is attached directly to the
frame. The section on the other side next to the brake cylinder is
really challenging as there is little room. (You will notice that
there are no close-ups of these welds) |
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There have been some questions on the
possibility of removing the gas tank with the subframe installed. I
need to remove the tank to install a high capacity fuel pump. I made
this discovery after I had already welded the subframe inplace. By
cutting a section from the subframe and removing the sheetmetal
directly in back of the tank, it is possible to remove the brackets
and pull the tank out. I welded plates on either side of the section
that I removed and then drilled through the plates and subframe. I
will bolt this piece back in place when I replace the gas tank. |
There
have been some questions on the possibility of removing the gas tank
with the subframe installed. I need to remove the tank to install a
high capacity fuel pump. I made this discovery after I had already
welded the subframe inplace. By cutting a section from the subframe
and removing the sheetmetal directly in back of the tank, it is
possible to remove the brackets and pull the tank out. I welded plates
on either side of the section that I removed and then drilled through
the plates and subframe. I will bolt this piece back in place when I
replace the gas tank |
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I got
the linkage connected. It involved threading the ends of the Northstar
cable and the Fiero cable. I used the rods supplied by IFG to tie the
two together. I can now shift gears from inside the car.. Cool...... |
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I
added the diagonal braces from the stretch to the bottom of the door.
I used 2" tube. This should provide an extra bit of rigidity to the
car. |
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I can now drive my car!
I was able to get brakes hooked up
and with the adapters, I could mount my wheels. This is the way my
Friday went just to give you an idea what kit car builders go through.
I had the 6000 spindles, but was missing two bolts and one axle nut
(dealer items). I went to the dealer and was able to pick them up.
They had to be ordered last week. I returned the Alante Rotors because
they were vented and would not go with the 88 Buick Riviera calipers.
I got Pontiac 6000 STE (four wheel disk version) rotors that would fit
the Alante Hubs. I took back the Riviera rotors and went with the
Pontiac 6000 STE calipers because they would accommodate the Fiero
brake cable. Got the rotors installed and went to figure out how to
mount the calipers and found out the guide pins were wrong size. It
looked like I would have to fabricate a bracket. (I'm getting good at
fabricating things by now) Went to wrecking yard to see if they had
any brackets that could be adapted to fit. Two wrecking yards later, I
decided to go the the dealer. He was out of stock. Decided to try
O'Riley's auto parts. They had guide pins but they wouldn't fit my
calipers. I went to Van's Auto parts where I bought the 6000 STE
calipers and they told me that the calipers that I had in hand were
for a 4 wheel drive Pontiac. The guide pins were correct, the calipers
were wrong. The main store down town had the correct calipers and they
were open till 8:00. I took the 4 wheel drive versions back and got
two Pontiac 6000 STE rear calipers and headed home. They bolted
directly to the 6000 spindles. Guide pins were included with the
calipers. I went to supper and on the way back decided that I should
replace my rear hoses with new ones. O'Rileys was still open and were
out of stock but the other store had two and could have them by 9:30
Saturday morning. Done deal. Went home dreaming of driving my car on
Saturday. Saturday morning up early, removed old hoses, Bolted on last
caliper about time Frank arrived. I needed to move two of the boot
clamps on the Northstar axle out a little as the boot was pinching
because the shaft had been shortened. Frank did that while I removed
the emergency brake mechanism from the 84 calipers. Oh, by the way.
The Pontiac 6000 STE calipers are exactly the same as on an 84 Fiero
caliper. This was good because I could now get back my $110 core
charge. By now its 9:30, call O'Rileys, hoses aren't in, should be in
by 12:30. Meantime, I can't get emergency brake brackets our because
the star bolts won't break loose. Drill them out, get the brackets but
now I need some bolts to hold the emergency brake bracket to the
caliper. Frank and I head to Van's to see if they have bolts and get
another star socket and brake bleeding kit and turn in the Fiero cores
to get my $110. No bolts at Vans, head to O'Rileys. Hoses are in, no
bolts. Stop at ACE hardware and they have bolts that will work.
Progress. Head home, hook up hoses, Frank attaches hose to first
caliper and the calipers threads are stripped and won't hold the hose
bolt. Pull the caliper, head back to Vans to see if I can get my 84
core back so I can at least hook up the brakes. They still have my
core, they order new caliper from other store which will be in on
Monday. Head back home, Frank has got the other brake line connected
to caliper, hook up old 84 Fiero caliper and new hose. Bleed brakes.
Throw in old seat. Start car, back out of driveway. Test brakes. Frank
gets in and we head down the street. I guess now is the time to see
what this Northstar will do so I punch it a little. WOW. So now I
decide to really hit it. MY GOD! This is probably more car than I have
ever driven. It will set you back in your seat and get your adrenaline
going. Sunday I put in one of the leather seats for a trial fit. |
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I
added a brace in front of the rear radiators. I will tie in the
radiator frame with a strap ( yet to be installed) as indicated where
the yellow lines are |
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I
started fabricating the plate to hold the shock bracket. The first
picture is the plate welded to the angle iron. The second picture is
the plate positioned inside the wheel well. I have not drilled the
holes yet for the shock bracket. The third picture is the bracket
clamped to the side of the dash where it will be welded. These
pictures are on the passenger side. |
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Here
are the openings and the bolt holes that have been drilled. You can
see where the coating was removed inside the bezel to epoxy the bolts
in. I sprayed the outside with primer and will paint them a candy
apple red with clear coat when I am done. |
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I
attached 1" square tube to the inside of the car that will be used to
attach the edge of the car to the rail along the bottom of the car. I
did not cover the rod in all places as I will be welding pieces to it
when attaching it to the car. |
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I
attached a 1" square tube from the center to the side wall to give the
edge more rigidity. I notched the frame to accommodate the 300ZX
headlights. I filled in the area with plate steel. I built a frame to
support the front of the spare tire area that will also act as an
anchor for the straps that cover the radiator. |
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I
filled in the original round opening that I had cut for the gas tank
and created the new opening in a better position to accept the filler
component off of the Fiero. This week I glassed the inside with mat. I
used epoxy to attach the fiberglass cutout to the Fiero gas cap. |
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Because my roadster was one of the first ones built, IFG has made
several improvements in the later models. The new roof section has a
arc that matches the inside of the roof panel and a slight backward
slope. Ray sent me the new section and I cut it in and added a new
steel section which I will glass in. I left the steel under the old
section until the new piece was glassed in and then I cut out the old
bar and replaced it with a 1" tube that I bent to match the roof line. |
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I got
the gas cap door working. I still need to finish the inside area. The
area to the left of the cap is where I had cut the opening in the
wrong place the first time. |
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I made
a 1" square tube frame to go along the bottom of the front bumper. I
will attempt to tie this into the frame once the car is finally
mounted. |
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I
painted the trunk area and removed all the water pipes and painted
them blue to match the motor area. |
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I took
a few shots as a refresher now that the body prep is nearing
completion. |
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I got
a rod kit from Jegs and made a strut brace for the rear struts. |
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I made
necessary changes to the door to fit my modifications of narrowing the
door. I test fitted the weatherstripping to make sure I got a good
fit. I then installed the rocker pannels by pop riviting them in at
the bas and then glassing the top edge to the inside door lip. |
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Beginning the sanding process. I used masking tape along the body line
and sanded with 80 grit sandpaper to the edge of the tape, moved the
tape to the sanded line and then sanded the other body panel. This
will help define the line when painted. My wife Cheryl is helping out
with the sanding and keeping me going. I can't tell you how important
it is to have a partner who is supportive of your project. I am very
lucky. |
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Installed the motorized antenna. It automatically retracts when power
is turned off. If will not interfere with the roof pannel and it just
seamed like a good place to put it. |
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Built
a bracket to cover the wiring and hoses next to the firewall. I
actually installed one more brace not shown where it angles down. I
then cut sheet metal to fit around the wires and hoses and painted to
match the rest of the interior panels |
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