Fiberfab Aztec 7 Manual de usuario
Table of Contents
Construction Material, Tools and Power Tools
Selecting a VW To Use For Your Aztec 7
emoving The VW Body
Disassembling The VW
Chassis Preparation
Softening Front Suspension
Decambering ear Suspension
Installing Tail Section Supports
Installing Heater Vent Tubing
Mounting The Voltage egulator
Installing Gauge Sending Units
Installing The Center Console
Installation of Spedometer Cable
Main Body Preparation
Cutting the Windshield Opening
Cutting the ear Window Opening
Cutting the Door Openings
Defroster Installation
Windshield Wiper Motor Installation
Drill Holes for Wiring Harness
Preparation of Dash and Overhead Console
Installation of Gauges and Switches
Installation of Dashboard
outing the Main Body Wiring
Installing the Main Body on the Floor Pan
The Gull-Wing Doors
Preparing the Gull-Wing Doors
Cutting the Side Window Openings
Preparing the Door for Latches
Locating the Door Hinges
Mounting the Door Hinges
Installing the Door Assist Cylinders
Installing the Door Latches
Fitting the Striker Plates
Installing the Door Stops
Preparing the Door for the Installation of Side Glass
Installing the Side Windows
Installing the Headlight Dimmer Switch
Detailing the Interior
Installing Headliner
Installing the ear Firewall Upholstery
Installing Upholstery on Front Firewall
Installing Side Panels
Installing Door Flange Trim
Upholstering Center Console
Installing Shifter Boot
Installing Floor Mats
Installing Door Panels
Installing Heater Vents
Installing Overhead Console
Installing Steering Shaft
Installing the Steering Wheel
Installing Side Glass Weather-strip
Installing ear Glass
Installing Windshield
Installing the Seats
Tail Section
Installing ear Bumper
Installing License Plate Lights
Weather Stripping
The Nose Section
Assembling the Headlight Boxes
Installing the Headlight Units
Installing the Front Bumper
Fastening the Nose to the Main Body
Installing the Nose Supports
Wiring the Front of the Car
Installing the Brake Fluid eservoir
Installing the Hood
Installing Locking Hood Hold-down Pins
Gas Tank Installation
Painting
Mirrors and Trim
Bolt Descriptions
Bolt Kit Listing
Wiring Harness
Templates
ear Glass Opening
Driver’s Side Template for Veneer
Passenger’s Side Template for Veneer
Overhead Console Switch Holes
CONSTRUCTION MATERIAL, TOOLS AND POWER TOOLS
Essential Hand Tools 1. Complete Socket Sets-both Metric and Standard
2. Screwdrivers-both Standard and Phillips
3. Straight – Edge
4. Tape Measure
Helpful Hand Tools 1. Open End and/or Box Wrenches
2. Pop ivet Gun, Various Size ivets
3. Wire Terminal Crimping Tool
4. Hacksaw
5. Set of Wood Working Hole Saws or Adjustable Hole Cutter
Essential Power Tools 1. Electric Drill
2. Jigsaw
Helpful Power Tools 1. otary Sander/Grinder
2. Hydraulic Floor Jack and Jack Stands
Essential Construction
Materials 1. Assorted Sheet Metal Screws
2. 40, 120, 240 and 400 grit Sandpaper
3. Electrical Tape
4. Silicone Seal
Helpful Construction
Materials 1. Epoxy Adhesive Kit
2. Epoxy Putty/Filler
3. VW Service Manual
SELECTING A VW TO USE FOR YOUR AZTEC 7
First, the variants (Fastbacks and Square backs) and Super Beetle series are not suitable.
When buying a VW to use with your Aztec 7 kit, remember the necessities are the floor pan, complete front end,
transaxle and engine. If these parts are complete and not damaged, the car is useable. Don’t be fooled by a bent-up
rusted body.
The following inspection checklist can be used as a guide to aid you in choosing a chassis/engine system:
1. Floor pan – check for bent flanges, rust, cracks and dents
2. Front End – check for collision damage, bent tie rods, worn ball joints, bent shock towers, worn steering gear and
bearings.
3. Transaxle – check for proper clutch operation and smooth shifting; listen for noise from gears and universal joints
while rolling the car forward; inspect trans case for leaks and metal chips in oil.
4. Brake System – check for scored brake drums, leaky wheel cylinders, spongy pedal.
5. Engine – inspect engine oil for leaks, low compression and smoking exhaust.
Description of Model Year, Engine and Chassis
1961-1965
Engine 1200CC-40 hp
All Synchromesh transmission
Swing arm rear suspension, link pin front suspension
1966
Hp increased to 50 hp
Ball joint font suspension
1967
Engine 1500cc-53 hp
12 volt electrical system
Dual brake system
Two speed windshield wipers
1968
Auto stick shift
4 bolt wheel pattern
1969-1970
Engine 1600cc – 57 hp
Swing axel replaced by CV joints
Steering column and ignition lock
1971
63 hp
1972-1973
VW diagnostic system installed
1975-1977
Electronic Fuel Injection
Alternator with integral regulator
REMOVING THE VW ODY
Tools Necessary Metric wrenches and sockets – 16mm to 19mm
1-1/8 inch socket
Standard and Philips Screwdrivers
Hammer
Cold Chisel
Penetrating Oil
VW Service Manual
Parts to Save From VW Body
Chassis, engine, transaxle and front end
Complete Steering Column and hardware
Voltage egulator
Gas Tank and Gas Tank Mounting Clips
Battery
Brake Fluid eservoir and Hoses
Headlight Dimmer elay
All Body Mounting Bolts and Body Washers
DISSASSEM LING THE VW
1. emove the front and rear seats
2. emove the battery (save brackets)
3. emove voltage regulator
4. emove the four bolts from the rear body mounting flange (save)
5. emove the bolt from each side under the rear seat back cushion
6. emove the seat belts
7. Disconnect the speedometer cable from the left front wheel
8. Pull the speedo cable through the hub by pulling it from the inside of the spindle.
9. emove the cardboard covers over the dash and gas tank in the luggage compartment.
10. Locate and remove the headlight dimmer relay and save
11. emove the speedometer cable by disconnecting the cable from the speedometer and pulling the cable out of the
body.
12. Drain the fuel tank
13. emove the four gas tank brackets and bolts. (save the brackets)
14. Disconnect filler hose from the tank. (’68 and later)
15. emove the fuel tank and set aside for use later
16. emove the brake reservoir complete with metal hoses. Leave the flexible rubber connecting hoses on the master
cylinder. Two 5/16 inch bolts will work well.
17. Disconnect the wires from the brake master cylinder switches
18. Identify the wires into the passenger compartment through the hole in the dash under the steering column
19. Pull these wires into the passenger compartment through the hole in the dash under the steering column.
20. emove the horn ring cover with a small screwdriver
21. Disconnect the ground wire at the horn ring.
22. emove the steering wheel nut and spring washer.
23. emove the steering wheel with horn ring.
24. emove the turn signal canceling cam from the bottom of the steering wheel and save it.
25. emove and save the retaining circlip from the steering column
26. emove the bolts that secure the steering column bracket to the dash.
27. Pull the steering column housing off the steering column shaft. Also remove and save the rubber grommet at the
base of the housing.
(NOTE: If vehicle was equipped with a locking steering column, the ignition key must be switched "on"
before the housing can be removed.)
28. To remove the steering column shaft: unbolt the steering shaft from the steering box at the flexible coupling. Save
the bolts and nuts for use later. Push the steering shaft toward the passenger compartment. When the flexible
shaft is free from the steering box, pull the shaft up and forward, out of the body.
29. emove the bolts that secure the body to the front torsion tubes beneath the area occupied by the gas tank. Save
these bolts.
30. aise the rear of the car and remove the rear wheels. ear body mounting bolts will be found just forward of the
shock absorber mounts. emove these bolts. Make certain the car is securely supported as considerable force
may be necessary to remove these bolts.
31. emove the flexible tubes between the heat exchangers and the body.
32. On newer models, remove the rear equalizer spring (stabilizer bar).
33. eplace the wheels and lower the car to the ground.
34. Disconnect the wiring from the main harness to the engine. These wires will be:
a. From the oil pressure sender located just below the distributor
b. Two wires on the generator
c. The wires on the starter motor
d. The wire from the main harness to the coil.
35. Working under the car with the car on the ground, remove all body bolts. Save the "U" shaped washers.
emoving the Body
Before trying to lift off 'the body, make certain the following steps have been performed.
1. All body bolts removed.
2. Steering column disconnected and removed.
3. Engine and brake wiring removed.
4. Heater hoses removed.
5. ear stabilizer bar removed (newer models).
The body can now be lifted off with a block and tackle or several strong friends. Lift the body to the side of the
chassis, not over the front or rear.
CHASSIS PREPARATION
efer to Figure 4
1. Now is the time to repair or replace worn engine, chassis, transmission, and suspension components because
they will be easily accessible.
2. emove battery brackets from the floor pan with a cold chisel.
3. Chisel off the two back seat heater cable tubes.
4. Using a hacksaw, saw off the jacking sockets flush with the edge of the floor pan flanges.
5. Use a cold steel chisel again to remove the seat rails on both sides of the pan.
6. epair any floor pan damage using fiberglass cloth and resin. On small holes use silicone sealant. These
materials are available at most auto supply stores.
7. Clean the entire chassis. This can be done at home with engine degreaser or by professional steam cleaning.
Steam cleaning is advisable.
8. After chassis has completely dried, remove all rust, using a wire brush.
9. Paint the entire chassis with a good rust preventive paint.
Figure 4a VW Chassis
Figure 4b emoving Seat ail
SOFTENING FRONT SUSPENSION
Because the Aztec 7 fiberglass body is lighter than the Volkswagen body, the front suspension must be modified or
"softened," to compensate for the weight reduction.
Tools equired Wrenches
Screwdrivers
Scribe
Welding torch -Optional
efer to Figure 5a and Figure 5b
1. Place the front of the chassis on jack stands.
2. Disconnect the brake lines on each side of the l-beam, by removing the holding clips and unscrewing the
connecting lines.
3. Disconnect the front suspension from the chassis, by removing the four bolts on the l-beams.
4. Scribe two lines around the lower torsion bar tube housing, 2" to the right and 2" to the left of the center bolt on
the tube. .
5. Using a pipe cutter, cut around the torsion bar tube housing, along the lines scribed in Step 5. Cut only through
the tube housing do not cut the torsion bars enclosed within the housing.
6. e-install the front end on the chassis. Do not re-connect the brake lines and steering damper at this time if you
plan to do your own welding. When the procedure is complete, the 4" cut portion of the housing (with the center
bolt) should move freely from the remainder of the housing when weight is applied.
7. Place approximately 175 lbs. of weight on the front of the I-beam. (A person standing on the l-beam will
accomplish this.) With the proper weight applied, the lower torsion bar should be 8" from the ground.
8. Tack weld the center portion of the tube housing back to the sides of the tube housing in the same, weighted
position obtained in Step 7. (NOTE: All welding can be done when the car is totally assembled. The car can
be driven to a gas station for welding.)
9. emove the I-beam from the chassis and permanently weld the center of the torsion bar tube housing to the side
housing.
10. e-install the I-beam onto the chassis. econnect the brake lines using the original clips, etc.
NOTE: Step #8 to be done with tires to be used on chassis.
NOTE: Stock VW shocks are recommended. The height can be reduced by cutting the rubber stops at the top of shocks
in half.
Figure 5A Front Suspension
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