THE JAMAICAN

The JAMAICAN is Fibeifab's newest entry in the aged rusted-out, leaky bodies it is designed to

field of ul tra-modern automotive body design. The replace. Comfortable and weathertight, the JA-

JAMAICAN is designed to capture in fiberglass MAICAN is rust and corrosion proof making i t a the very latest trends in sports and GT Styling - pract ical as well as a beautiful conversion. smoother I ~nes ; uncluttered, graceful contours; all combined with the look of power. Not only does the design of the JAMAICAN in-

corporate the ult imate in styling and utmost in The JAMAICAN 1s s~r i tab le for use on a number of

comfort it also gives considerable a t ten t~on to readily available sports c3r chassis. The use o f

the exist,ng ,netal f l o o r panels o f the d r ~ v e r s<ifety - all the JAPVIAICAN window open-

various chassis, coupled w ~ t h the bul l [ - in panel ing lngs are designed to accept readily available

of the JAMAICAFI body, provides easy ~ n s t ~ i l l a t ~ o n crulomotlve s ~ f e t y glass, ~nc lud ing rol l up side

on the PVIGA, A u s t ~ n He.iley J. A u s t ~ n Ht:L~l~,y C j w~ndows , p ro i~ ls lon for ~r i tegra l roll bar ' , rein-

T r t l~ lnph TR-3 TI?-4 ,incl \/LV fr?r(:r>ll ~ ~ ~ ~ ; c l ~ ; l i t ~ : I ~ i ~ p t l n ~ n q

The JAPVIAICAN CiT coupe j t y l l n ~ j ~; r ,~f tc t~ l In t~t,l?r-

2365 LAFAYETTE F I B E R F AB sA,-ra =LA-1, c n L , F . ssoso r

H e r e a r e y o u r J a m a i c a n M o u n t i n g I n s t r u c t i o n s . T h e y

i n c l u d e a l l t h e d r a w i n g s , p a r t s l i s t s , e t c . y o u w i l l

r e q u i r e t o c o m p l e t e y o u r c a r . H o w e v e r , b e f o r e y o u

p e r u s e t h e p l a n s l e t ' s c o n s i d e r t h e t o o l s y o u ' l l n e e d

a n d a f e w s o u r c e s o f c h a s s i s .

A l l o f o u r f a c t o r y c a r s , l i k e t h e o n e s s h o w n i n t h e s e

i n s t r u c t i o n s , a r e b u i l t u s i n g n o m o r e t h a n t h e o r d i n a r y

h o m e w o r k s h o p i n v e n t o r y o f t o o l s . W e r e c o m m e n d , a s

a m i n i m u m " J a m a i c a n W o r k s h o p " , t h e f o l l o w i n g :

1. 1 / 4 " e l e c t r i c d r i l l

2 . 1 / 8 " , 1 / 4 " , 3 / 8 " ( w i t h 1/4"shank) d r i l l b i t s

3 . O n e s e t o f w o o d w o r k i n g h o l e s a w s

4 . I < e y h o l e s a w o r e l e c t r i c s a b e r s a w

5 . M e d i u m b l a d e standard a n d phi l l ips s c r e w d r i v e r

6 . 3 / 8 " , 1 / 2 " , 9 / 1 6 t 1 s o c k e t s , w r e n c h e s , e t c .

7 . S t r a i g h t e d g e

8 . S t e e l t a p e

9 . A s s o r t e d r a s p s

W i t h r e g a r d s t o t h e p r o c u r e m e n t o f a c h a s s i s - - i f

y o u ' r e n o t a l r e a d y d r i v i n g i t - - i .41~ h a \ ~ ~ ! f o u n d t h e a u t o w r e c k i n g y a r d s t o b e a g o o d

s o u r c e o f c h a s s i s - - l o c a l l y w e h a v e a d i r e c t o r y c a l l e d

a P A R T S L O C A T O R w h i c h l i s t s t h e v a r i o u s y e a r s a n d

m a k e s a v a i l a b l e t h r o ~ r g h o u t o u r t e r r i t o r y . Y o u s h o u l d

c h e c k t o s e e i f a n e q u i v a l e n t g u i d e i s a v a i l a b l e i n

y o u r l o c a l e .

A n o t h e r s o u r c e i s y o u r i n s u r a n c e a g e n t - - a s k h i m t o

r i o t i f y y o u i f h e p r o c e s s e s a n y " t o t a l w r e c k " c l a i m s

i n v o l v i n g t h e c h a s s i s - t y p e y o u ' r e a f t e r . F i n a l l y ,

c h e c k t h e c l a s s i f i e d a d s i n y o u r l o c a l p a p e r s u n d e r

t h e " a u t o p a r t s " h e a d i n g s - - m a n y t i m e s a u s a b l e

c h a s s i s i s l i s t e d b y a n o w n e r b e f o r e h e s e l l s i t t o

a d i s m a n t l e r .

N o w o n t o t h e d e t a i l s . . . . . . . . .

Note: These instructions represent the principal corr~position of the total Jamaican Mounting Instructions Package. Some ver detailed X material is withheld and w i l l be sent wi th your body. In i s manner we can always introduce up-to-m inute changes into the instructions- ---changes which occur inevitably as a result of our continuing pro- gram of product refinement and improvement.

THE COST OF THESE INSTRUCTIONS W I L L BE REFLlNDED ON RECEIPT OF

YOUR F I R S T ORDER. 1

1. C H A S S I S R e q u i r e d :

Frame and suspension (incl. hubs) Engine (unless considering engine swap) Transmission, propellor shaft, rear axle Steering assembl y, brake system Pedal Assembly, (clutch, brake, thrott l e) Some inner panell ing (see figure 2 ) Gas tank, Trans. & shaft tunnel covers F loor boards (MGA), radiator

D e s i r a b l e : Original wiring Heater Instruments Wheels and t ires

2.. J A M A I C A N D O O R H A R D W A R E Door Hinges - two sets of hinges are required

Windows - le f t and r ight door windows

Regulator mechanisms

Weather str ipping - one windlace k i t

Window opening weather str ipping Mathers t r ipp ing chrome tr im Outside and inside wiper rubber

Outside wiper chrome tr im Door Latches - Option 1 (for handleless key

only operation): DOOR LATCHES

Door lock cyl inder Striker Studs

Door Latches - Option 2 (~j$. ,hgd!es!- Use standard hardware: Latches, Kandles, and str iker studs.

3 . W I N D S H I E L D S a f e t v G l a s s w i n d s h i e l d ( i n c l u d e d

w ~ t h r n e u e i u x e K I L ; Rubber Molding Chrome Molding and retainor c l i ps

4 . R E A R W l l V D O W 'a;::{ G l a s s W i n d s h i e l d ( i n c l u d e d t h e D e l u x e K i t ) Rubber Molding

Chrome Molding

Aust in Healey, MGA1TR3,TR4

Ford CODB 6 4 2 2 8 0 0 A rt. tp. Ford CODB 6 4 2 2 7 0 1 A I f . tp. V W 1 4 3 8 4 5 2 0 1 A & 2 0 2 A (glass) 1 9 6 0 - 6 3 Karmann Ghia (also 6 0 - 6 3 Karmann Ghia) 5 5 1 B . 5 5 2 B . 5 7 1 A . 5 6 5 A ~ ~ 1 4 1 8 3 7 5 0 1 ~ & 5 0 2 ~ Standard w/upholstery k i t or i s available from Fiberfab VW 1 4 3 8 4 5 2 1 1 A & 2 1 2 VW 1 4 3 853 3 3 7 A & 3 3 8 A Somaca B - 6 0 5 (4ea. l ( 6 1 - 6 3 GM cars) VW 1 4 3 853 5 1 6 A (2ea. l

Ford C 4 5 Z - 6 3 2 1 8 1 3 - C Ford C 4 5 Z - 6 3 2 1 8 1 2 - C Ford C 5 0 Z - 6 2 2 1 9 8 4 - A 1 Ford C 2 0 B - 6 2 2 0 0 0 8 Ford C 2 0 B - 6 2 2 0 0 0 9

Karmann Ghia

1 9 6 3 - 6 6 Corvette Stingray

Chev. 3 8 4 4 0 4 9 Chev. 3 8 4 1 2 5 1 ( l e a . Chev. 3 8 4 1 2 5 5 ( l e a . ) Chev. 3 8 5 9 0 4 4 (2ea. l Chev. 3 8 5 9 0 4 5 (2ea. l Chev. 3 8 4 3 9 3 9 (20ea . l

I Porsche 9 0 1 5 4 5 1 0 1 2 0 Porsche 9 1 2 Rear Window Porsche 9 0 1 5 4 5 9 1 1 2 0 Porsche 901 5 4 5 912 20 Porsche 9 1 2 Rear Window Porsche 6 4 4 5 4 1 9 2 1 0 6 Porsche 9 1 2 Rear Window

5 . H O O D H e a d I i g h t s : high b e a d l o w beam combination

units (identif ied by 3-prong connector) with mounting brackets and chrome bulb retaining ring, such as the sealed beam units standard on Austin-Healey MGA and TR.

G r i I l : Any gr i l l oC our choice f i t t ing an opening measuring 5 " x 44" overal I. Suggested g r i l l include egg-crate (Camaro), horizontal bar, and expanded metal (available at most hardware stores)

P a r k / t u r n i n d i c a t o r l i g h t s : select dual-element 1 2 v bulb units compatible with your g r i l l selection. The l ights standard on your chassis w i l l probably suffice.

H o o d L a t c h : Option 1: Side Mount Option 2: Center Mount

6 . O T H E R B O D Y H A R D W A R E T a i l l i g h t s : Any f la tpane l mountedtail

l ight units of not more than 7" high or 8" wide may be uti l ized.

L i c e n s e p l a t e l i g h t / b r a c k e t : Combin- ation holder and l ight available at most au to supply stores.

G a s t a n k f i l l e r c a p : Standard Austin- Healey, MGA or TR cap or chrome fl ip-top cap available from Fiberfab.

7 . I N S T R U M E N T S I f the stock gauges are not functioning or are not avail able, Fiberfab can supply replacements out of the extensive Stewart-Warner line. The following items may be ordered from your local Stewart-Warner dealer or directly from us.. . . .

Fuel level gauge Fuel level sender Instal lation k i t

Water temperature gauge Temperature sender

O i l pressure gauge Pressure sender

Ammeter

Speedometer (1 6 0 M PHI O t h e r O p t i o n a l I n s t r u m e n t s

Oi l temperature gauge Temperature sender

Triumph Spitf ire Austin-Healey or MGA

Austin-Healey, MGA,or TR

STEWART-WARNER NO.

3 0 1 - A W 3 8 5 - C 3 6 6 - L P

3 1 1 - C F See Water Temperature

Tachometer Tachometer sender

I 548 Baldwln Street Brldgevllle. Pennsylvania 15017 Phone 472 221-6200

J A M A I C A N S E R I E S P R I C E L I S T

J A M A I C A N S E R I E S B A S I C BODY K I T S :

A A I B A S I C BODY K I T S FOR T R 3 , T R 4 , T . R b A , T R 6 , T R Z S O , MGA, A U S T I N H E A L E Y 3 0 0 0 .

J A M A I C A N I I B A S I C BODY K I T FOR VW OR KARMANN G H I A . J A M A I C A N ! I - V 8 F R A M E * A N 0 B A S l C BODY K I T F O R F R O N T MOUNTED v 8 .

E F F E C T I V E 7 / 1 / 7 6

* T H E J A M A I C A N I I - V 8 FRAME K I T I S A S U P E R S O P H I S T I C A T E D I N D E P E N D E N T S U S P E N - S I O N A N D POWER T R A I N . T H E J A M A I C A N l l - V 8 F R A M E I S A L A D D E R F R A M E C O N S T R U C T E D O F 5" X 2 " X . I 2 0 S T E E L T U B I N G , H E L I A R C W E L D E D T O G E T H E R I N A S T A B I L I Z I N G J I G . A S P E C I A L F L O O R P A N I N T H E J A M A I C A N 1 1 - V 8 BODY L O C K S T H E BODY I N P L A C E ON T H E F R A M E . T H E F R A H E I S E N G I N E E R E D T O A C C E P T A S M A L L B L O C K C H E V Y V 8 FORWARD MOUNTED. C O U P L E D TO A C O M P A T I B L E S T A N D A R D OR A U T O M A T I C T R A N S M I S S I O N . T H E F R O N T S U S P E N S I O N I S C O R V A I R ( ' 6 6 OR N E W E R ) , T H E T H I R D MEMBER I S C O R V E T T E ( ' 6 3 OR N E W E R ) , A N 0 T H E R E A R S U S P E N S I O N I S C O R V A I R ( ' 6 6 OR N E W E R ) . C O R V A I R R E C I R C U L A T I N G B A L L T Y P E OR P I N T O R A C K h P I N I O N T Y P E S T E E R I N G MAY BE U S E D . T H E NEWEST J A M A I C A N l l - V 8 K I T U T I L I Z E S T H E CAHARO F R O N T S U B F R A M E A 9 D T H E C H E V E L L E R E A R A X L E A S S E M B L Y .

J A M A I C A N S E R I E S B A S I C BODY K l T S I N C L U D E :

1 . M A I N BODY W I T H I N N E R P A N E L S . 2 . FORWARD NOSE S E C T I O N ( O N E - P I E C E T I L T C O N F I G U R A T I O N ) F O R J A M A I C A N I K I T S O N L Y .

FORWARD N O S E S E C T I O N AND S E P A R A T E HOOD F O R J A M A I C A N II A N 0 l l - V 8 K l T S O N L Y . 3 . E N G I N E A C C E S S / T R U N K L I D F O R J A M A I C A N I I A N D l l - V 8 K I T S O N L Y . 4. ONE P A I R DOORS. 5 . O N E P A I R F I B E R G L A S S G T S E A T S H E L L S ( N O T U P H O L S T E R E D ) .

E A S Y R I D E R S E A T S H E L L S W l T H H E A D R E S T A R E O P T I O N A L AND $ 3 0 . 0 0 A D D I T I O N A L . 6 . ONE D A S H P I E C E . 7 . F R A M E K I T FOR J A M A I C A N l l - V 8 K I T O N L Y . . 8. ONE F I B E R G L A S S T R A N S M I S S I O N C O N S O L E - C O V E R F O R J A M A I C A N 1 1 - V 8 K I T O N L Y . 9 . A S S E M B L Y M A N U A L . ( M A Y B E O R D E R E D I N A D V A N C E F O R $ 1 0 . 0 0 . ) S P E C I F Y C H A S S I S .

J A M A I C A N S E R I E S O P T I O N S :

VDO C O C K P I T GAUGES 1 2 V O L T O N L Y : S P E E D O M E T E R T A C H O M E T E R AMMETER F U E L GAUGE O I L T E M P E R A T U R E GAUGE O I L T E M P E R A T U R E S E N D E R

VDO C O C K P I T GAUGES F O R J A M A I C A N l l - V 8 O N L Y : S P E E D O M E T E R T A C H O M E T E R AMMETER F U E L GAUGE O I L P R E S S U R E GAUGE O I L P R E S S U R E S E N D E R WATER T E M P E R A T U R E GAUGE WATER T E M P E R A T U R E S E N D E R

I N T E R I O R U P H O L S T E R Y , B L A C K O N L Y . c r S E A T C O V E R S , B L A C K O N L Y , P A I R . E A S Y R I D E R S E A T C O V E R S , B L A C K O N L Y , P A I R .

T H E J A M A I C A N S E R I E S BODY K l T S A R E NOW O F F E R E O I N P R E - A S S E M B L E D FORM. T H E BODY I S T O T A L L Y A S S E M B L E D . J U S T MOUNT TO YOUR C H A S S I S . c o n P u l E F R o n P R I C E L I S T I T E M S D E S I R E D . ADO L A B O R C H A R G E O F $ 1 2 0 0 . 0 0 F O R J A M A I C A N I A N 0 l l K I T S , $ 1 5 0 0 . 0 0 F O R J A M A I C A N 1 1 - V 8 K I T .

J A M A l C A N S E R I E S D E L U X E P A K ( O P T I O N A L I T E M S ) :

W I N D S H I E L D C L A S S C O R V E T T E ' 6 3 - ' 6 7 1 R E P . $ 9 8 . 0 0 E A . W I N D S H I E L D R E V E A L M O L D I N G C O R V E T T E ' 6 4 - ' 6 7 1 R E P . 3 5 . 9 4 E A . W I N D S H I E L D P O L Y T A P E 1 R E P . 9 . 0 0 E A . W I N D S H I E L D R E V E A L C L I P S 1 S E T 2 . 0 0 E A . R E A R G L A S S C L E A R P O R S C H E 9 1 1 - 9 1 2 I R E P . 1 4 6 . 2 5 € A . R E A R C L A S Z U A A ~ C ~ 1 R E Q . 3 5 . 6 3 E n . R E A R G L A S S R E V E A L M O L D I N G 1 R E Q . 4 7 . 5 0 E A . S I D E C L A S S K A R M A N N G H l A H A R D T O P ' 6 1 - ' 7 4 2 R E Q . 4 4 . 0 0 E A . S I D E G L A S S C A R R I E R C H A N N E L K A R M A N N G H l A H A R D T O P l 6 1 - ' 7 4 2 R E Q . 5 . 0 0 E A . S I D E G L A S S C A R R I E R G A S K E T K A R M A N N G H l A H A R D T O P ' 6 1 - ' 7 4 2 R E Q . 2 . 0 0 E A . S I D E G L A S S R E G U L A T O R K A R M A N N G H l A H A R D T O P ' 6 1 - ' 7 4 2 R E Q . 2 8 . 0 0 E A . S I D E C L A S S W I N D O W G U I D E T R A C K K A R M A N N G H l A H A R D T O P ' 6 1 - ' 7 4 2 R E Q . 2 9 . 1 0 E A . S I D E G L A S S H O L D I N G E X T R U S I O N 2 R E Q . 7 . 4 0 E A . S I D E G L A S S M O L D I N G E X T R U S I O N W E A T H E R S T R I P 2 R E Q . 9 . 4 0 E A . S I D E G L A S S W E A T H E R S T R I P I N N E R 2 R E P . 5 . 2 5 E A . S I D E G L A S S W E A T H E R S T R I P O U T E R 2 R E Q . 6 . 2 5 E A . D O O R H I N G E S L E F T M U S T A N G ' 6 5 - ' 6 7 OR P I N T O 1 S E T 1 9 . 9 5 E A . D O O R H I N G E S R I G H T M U S T A N G ' 6 5 - ' 6 7 O R P I N T O 1 S E T 1 9 . 9 5 E A . O U T S I D E B A T H A N D L E , L A T C H & C A B L E A C T U A T O R 2 R E Q . 2 1 . 5 6 € A . W I N O L A C E - DOORWAY S U R R O U N D 2 R E Q . 1 5 . 0 0 E A . H E A D L l G U T 2 R E Q . 2 4 . 3 0 E A . F R O N T T U R N S I G N A L 2 R E P . 5 . 6 7 E A . T A I L L I G H T 2 R E Q . 2 3 . 2 0 E A . I N D I C A T O R D A S H L I G H T 3 R E P . 2 . 6 7 E A . C H R O M E G A S C A P C O V E R I R E P . 1 1 . 0 1 E A . 0 1 M M E R SUI T C H 1 R E Q . 2 . 7 4 E A . S T B A T H A N D L E S W I T C H 2 R E P . 3 . 9 7 E A . I G N I T I O N S W I T C H W I T H K E Y S 1 R E P . 8 . 0 0 E A . H E A D L I G H T B A T H A N D L E S W I T C H I R E Q . 3 - 9 7 E A . I N S I D E R E A R V I E W H I R R O R 1 R E Q . 1 0 . 5 8 E A . W A L N U T S T E E R I N G W H E E L 1 R E P . 3 9 . 9 5 E A . W I R I N G H A R N E S S 1 R E Q . 4 5 . 0 0 E A . D E F O G G E R - D E F R O S T E R 1 R E Q . 3 9 . 5 0 E A . F E N D E R M O U N T M I R R O R - B L A C K P R I H E D 2 R E P . 9 . 0 2 E A . DOOR L A T C H H A N D L E I N S I D E , E U R O P E A N S T Y L E 2 R E Q . 6 . 6 5 E A . DOOR W I N D O W H A N D L E I N S I D E , E U R O P E A N S T Y L E 2 R E Q . 7 . 3 5 E A . W I N D S H I E L O W I P E R A S S E M B L Y . C O H P L E T E W I T H A R M S 6 B L A D E S I R E Q . 8 9 . 9 5 E A .

J A M A I C A N S E R I E S A C C E S S O R I E S :

O I L P R E S S U R E G A U G E 7 0 d O I L P R E S S U R E G A U G E S E N D E R F U E L T A N K F L O A T U N l T Q U A R T Z C L O C K F O U R - W A Y F L A S H E R S L I C E N S E P L A T E B R A C K E T A N D L I G H T C O N S O L E R O A D R U N N E R S T E E R I N G U H E E L - E U R O P E A N S T Y L I N G F O A M F O R M U L A GT S T E E R I N G U H E E L - L E A T H E R C O V E R E D S E A T A D J U S T E R S , 5 " T R A V E L , P A l R Q U I C K S H I F T K I T C U S T O M S I 1 I F T E R ' 6 8 - ' 7 4 V U C U S T O M S H I F T E R ' 5 6 - ! 6 7 V U P E D A L A N D A C C E L E R A T O R C O V E R K I T O I L C O O L E R A N D F I L T E R U N l T H I GH P E R F O R M A N C E A I R C L E A N E R F E N D E R M O U N T M I R R O R - C H R O M E H E A D L I G H T C O V E R S , P A I R G T S T Y L E F R O N T R U M P E R GT S T Y L E H E A R O IJMPER H E A D E R / D U A L M l l r F L E R C O M B I N A T I O t l

D E C A L S , B L A C K L E T T E R I N G , P A l R M E D A L L I O N , HOUtdU P E W T E R

C U R B U E 1 6 1 1 T : J A M A l C ; l N 1 , 1 6 0 0 6 , J A M A I C A N l l , 1 4 7 5 # , J A M A I C A N I I - v ~ , 2 1 0 0 6

L

KIT #I - STANDARD JAMAICAN KIT INCLUDES:

1 ) JAMAICAN body 7) Wide, fully flanged doorsills 2) Front hood hinges (prelaminated into body) 8) Rear window surround flange 3) Complete inner panels (to mount body) 9) Windshield surround flange 4) Headlight indents 10) Metal reinforcing inside windshield area 5) Dashboard 11) Side and front air scoops 6) Recessed license plate holder 12) Mounting instruction booklet

KIT #2 - DELUXE JAMAICAN KIT, includes everything in KIT #1, PLUS:

I 1 ) Safety glass windshield 3) Rear safety glass window 2) Door-inner panels for roll-up mechanism 4) Choice of GT, Classic or Lotus-type fiberglass

seat shells 1 Complete mounting and chassrs prepsratron instructions are included with each body order. Should you wish a copy prior to purchasing your body, the mounting booklet is available for $5.00 refundable with order.

JAMAICAN PRICE LIST

JAMAICAN Kit . ? I , St,jndclrd $795.00 JAMAICAN Klt s:?, Deluxe 895.00 JAMAICAN Deluxe Upholstery Kit (Blk) 195 00 JAtvlAICAbl P l e x ~ q l ~ ~ s s Hea r l l ~ f l h t Covtlrs 30.00

The following accessories included with the Deluxe K i t are also available separately:

T A B L E O F C O N T E N T S

C O N S T R U C T I O N M A T E R I A L S - - T o o l s a n d S u p p l i e s

W H A T T O L O O K F O R W H E N A C Q U I R I N G A W R E C K E D V E H I C L E : M G , T R , A U S T I N H E A L E Y

P R E P A R I N G T H E C H A S S I S - - W h a t g o e s ? W h a t s t a y s ?

IVIOUIVTING T H E J A M A I C A N B O D Y

I N S T A L L I N G T H E W I N D O W S A N D W I N D S H I E L D

W I R I N G A N D I N S T R U M E N T S

U P H O L S T E R Y - - I n t e r i o r F i n i s h

S A N D I N G , P R I M I N G A N D P A I N T I N G - - E x t e r i o r F i n i s h

V - 8 P O W E R O P T I O N

lo. J A M A I C A N / V O L K S W A G E N

I N T R O D U C T I O N

T h e f o l l o w i n g p a g e s c o n t a i n i n s t r u c t i o n s f o r a s s e m b l i n g t h e 1968 JAMAICAN.

T h e s e i n s t r u c t i o n s a r e i n t e n d e d t o c o v e r e v e r y p h a s e o f p r e p a r a t i o n , a s s e m b l y

a n d f i n i s h i n g r e q u i r e d t o b r i n g y o u r c a r - b u i l d i n g p r o j e c t t o a s u c c e s s f u l c o n -

c l u s i o n .

T o m e e t t h e d e m a n d s o f t h e m a n y p e o p l e w h o p r e f e r t l i e d r i v i n g " f e e l " a n d e x t e r n a l a p p e a r a n c e o f a f r o n t - e n g i n e d s p o r t s c a r , F i b e r f a b c r e a t e d t h e JAMAICAN.

D u r i n g t h p d e v ~ l o p m e n t o f t h e J A M A I C A N d e + i g n , i t e...4 r c l l i::d t l i ~ : z z r t a i n

u n i b o d y c a r s s u c h a s t l i e Austin-Healey S p r i t e a n d M G B w e r e n o t s u i t a b l e v e h i c l e s

f o r a " b o d y s w a p " . I n o t h e r w o r d s , r e m o v a l o f t l i e o r i g i n a l m e t a l b o d y r e m o v e d

t o o m u c h s t r u c t u r a l r i g i d i t y . N e v e r t h e l e s s , e l i m i n a t i o n o f t h e u n i b o d y c a r s s t i l l

l e f t t h r e e v e r y p o p u l a r f r o n t - e n g i n e d s p o r t s c a r s t o b e c o n s i d e r e d - - - - - - - - - - - - A U S T I N - H E A L E Y , M G A , a n d T R I U M P H .

W h e n y o u o r d e r y o u r JAMAICAN k i t , y o u c a n s p e c i f y t h e c h a s s i s o n w h i c h

y o u p l a n t o m o u n t i t , s o t h a t w h e n y o u r JAMAICAN b o d y i s p r o d u c e d , t h e p r o p e r

i n n e r f o r m o u n t i n g a r e l a m i n a t e d i n t o t h e b o d y - - t h u s t h e b o d y f i t s p r e -

c i s e l y o n j u s t t h e t y p e o f c a r y o u a r e c o n v e r t i n g .

1. C O N S T R U C T I O N M A T E R I A L S

The typical inventory of tools found in most home garages or basements w i l l probably more than suffice to complete your JAMAICAN. In real i ty, very few tools are absolutely essential to the conver- - s ion.

The following breakdown of tools i s based on Fiberfab factory ex erience.. Items that are con-

to make certain construction tasks significant1 y easier. f: sidered essential are listed. Another l i s t is also ~ r o v i d e d of items whic are q u ~ t e helpful and serve

HAND TOOLS

Essential

-5/16", 3/8", 7 /16" , 1 /2" , 9 /16" , 5 / 8 " sockets -- 3 / 8 " Drive -31.6'. L r ~ v e Rachet Handle -Standard screw-driver -- medium blade ---Phill ips screw-driver -- medium blade S t r a i g h t - e d g e

-3/8" Drive -- 3" and 6 extensions -3/811 7/16" , 1 /2" , / 1 6 " combination (open-end and box-end wrenches)

-Steel rule (72")

6 " ~ o p l ' r ivet gun -- home workshop variety

+ire-terminal crimping tool -Hacksaw - Knife - Assorted rasps, files, dr i l ls and taps -Set of wood-working hole-saws

POWER TOOLS Essential

-Electr ic dr i l l -- 1 / 4 " capacity Helpful

Electric dr i l l -- 1 / 2 " capacity Sabre saw Rotary sander/grinder Hydraulic floor-jack and jack stands

CONSTRUCTION MATERIALS

Essential Assorted .machine bolts and nuts; 1 /4" ,5 /16" and 3/8"; with washers and locking washers Assorted sheet metal screws Sandpaper Sil icone seal (common types are Rubber Sealant by the Macklenburg-Duncan Company of

Oklahoma City, Dow-Corning DC 7 5 0 , and General Electric) But I tape (windshield installation ki t) -- typical is Somaca#9103* 208 ' -300 ' # Z 6 AWG wire; 1 0 0 ' - 1 5 0 ' # 1 0 AWG wire ( i f chassis re-wiring required) Primer, paint, etc. Car seam sealer, 1 tube -- typical is 3W # 1 9 1 5 - 5 2 0 9

Helpful

Epoxy adhesive k i t ( high-grade epoxy, *body f i l ler type) Epoxy putty/fi l ler Crimp-on wire terminals Assorted "pop" rivets

* Somaca-Western, 8 5 2 Aldo Ave., Santa Clara, Calif. SOMMER AND MACA,5501 W.Ogden Ave., Chicago, I l l ino is * 3 M is the trademark of Minnesota Mining and Manufacturing

2 . WHAT TO LOOK FOR WHEN ACQUIRING A WRECKED V E H I C L E

Many persons purchasing a JAMAICAN body wis l i to replace the travelworli or weatllered "skin" of tlre vel l ic le they already own and are currently driving. Other builders plan to acquire a wrecked Aust in Healey, MGA or TR from a salvage yard and refurbisl i th is "outcast" w i th a new JAMAICAN body and perhaps some new nlechanical parts. In either instance, th is br ief sect ion should be of interest to a l l prospective builders.

In most areas o f the Uriited States, a t least three approaches to obtaining a suitable, salvageable sports car are available. The f i rs t approach i s to contact the local dealer i r ~ tfie vehicle of interest. He may have been asked to b id on insurance work and w i l l kriow tl ie ava i lab i l i ty arid locatiolr of wrecked vehicles. Tl ie second approacli is to ca l l several automobile irisurallce conlpanies arid ask about ariy recent wrecks they have declared to be " totals" -- marly tirnes i f the car i s earl ier than 1 9 6 0 atid the body damage is mod- erate to extensive, the car w i l l be " total led" even thougll under i t s rumpled sk in i s a m e m i c a 1 "jewel".

Tl ie third and most obvious aooroach is to ca l l the local salvaqe/wrecking yards -- ~ s y c i a l l y those ad- vert is ing a foreign car section. Some areas ot the U.5.; tor example, the San F ra r~c i sco Bay Area wliere Fiberfab i s located; have publications appearirig weekly or monthly w l ~ i c l i l i s t a l l wrecked vehicles and their location. The publicatiori we use is:

T H E PARTS LOCATOR 1696 Wastiirigton Avenue San Leandro, Cal i fornia

lrrfortnation concerning similar publ icat ions ill other loca l i t ies may be forthcornirig from tlie above address, upon request.

When a seemingly sui table wreck i s f i na l l y located, look i t over c lose ly in person, not v ia photographs. Don't l e t a mangled body dismay you or a clean-looking body fool you. Remember, you are interested pr imari ly i n the frame, drive-l ine, suspension a l ld engine -- broken doors, ripped seats, sliattered glass, etc., are o f not consequence.

Items to be checked are:

1. CONDITION OF ENGINE -- valve cover not crrrslred, carburetors intact, exhaust manifold not torn loose, pan secure and not leakilrg, radiator free of punctures, etc. -- try to get some kind of guarantee that the engine i s i n rurining condition.

2. CONDITION O F SUSPENSION -- a l l axles rotate, steering l inkage i s not bent or broken, A-frames (front suspension) unbent, etc.

3. CONDITION O F DRIVE-LINE -- wi t t i one rear wheel blocked from rotating, make sure the other rear wheel turns reasonable freely when the gearbox i s in neutral and does riot turn a t a l l when any gear i s selected (assuming, of course, that an engine i s i n place i n the veliicle).

4. CONDITION OF T H E F R A M E -- using a steel tape, measure the squareness of the frame; ie., check fore and a f t dimension between the wheel centers on both sides (the "wlleelbase") -- are they ident ica l? Look under the car and assure yourself that none of tlie frame members are crushed or bent.

I n addition, t ry to get as many pieces of aux i l ia ry equipment as possible a t the time you buy the "outcast" ---items such as windshield wiper motors, instruments, etc., w i l l probably be cheaper i n a "package deal" than i f you return later to purchase them separately.

A s an a id to acquiring a usable wreck and estimating i ts worth, some v i ta l s ta t is t ics are presented below:

AUSTIN-HEALEY

The Aust in Motor Company of Birmirrgliarn, England started bui ld ing the Austin-Healey 1 0 0 sports car i n 1952. The Austin-Healey 1 0 0 used the 2.6 l i ter , four-cylinder Aust in A 9 0 e ~ ~ g i l l e . Subsequent ver- s ions were the l O O M and 1 0 0 s ; both aimed a t competit ion events. The 1 0 0 s errgirie developed 132 BH P and had disc brakes.

Next i n the Aust in-Maley evolut ion was the 1 0 0 - 6 usirig a BMC, 2 . 6 l i ter , s ix cylir ider erigine. Some of the 1 0 0 - 6 models were produced wi th a s ix -por t l iead to obtain higher performarlce than the standard 1 0 0 - 6 eligine output of 1 0 2 BHP. 111 1959, a 3 l i t e r s i x cyl inder engine was irltroduced in tlre Austi l i-Healey 3 0 0 0 . T l ie 3 l i te r engine was avai lable for a br ief period ( 1 9 6 1 - 1 9 6 2 ) in a 3-carburetor version wl i ich proved qui te d i f f i cu l t to keep i n tune. Tlie Austin-Healey 3 0 0 0 had d i sc brakes (front) arid wire wheel options. Tl le wheelbase i s 9 2 inches.

MG - As early as 1 9 3 6 , the MG Company (now located at Abingdon, England), produced a vehicle suitable

for conversionwith a JAMAICAN body -- the MG, TA. This car featured a 1.3 liter, 5 0 BHP four cylinder englne. I n April, 1 9 3 9 the TA was replaced by a new model with minor refinemerlts, the MG fB. The total TA and T B production, before it was discontinued as a result of WWII, was only 3 4 0 0 cars.

Shortly after the war, the T B was revived in a new form as the MG TC which was soon followed by the TD. Both were equipped with 5 7 . 5 BHP engines. In 1 9 5 4 the 63 BHP TF 1 5 0 0 was introduced but was short-lived because in 1 9 5 5 production was commenced on the MGA which offered a 78 BHP en ine.

cam engine in place of the standard pushrod engine. R The MGA series offered several interesting options -- disc brakes (front), wire wheels and a twin over ead

In 1 9 6 2 , the MGB arrived on the scene but as previously mentioned, i ts unibod constructipn pre- cludes i ts use as a vehicle for the JAMAICA^. A l l of the cars listed above, except t l e MGB will accept Lilr ..iAMkiCA:i body i n a s ~ ~ l u c l ~ as they a l l have frames separable jrorll tile bodym~l; .i,,: t h q ;.\I hall? 9a" wheelbases.

Market response for the JAMAICAN has revealed, however, that 9 9 % of the bu ers using the body on MGs were using a MGA. Therefore, the JAMAICAN is inner-paneled to f i t the M G ~ series exactly although the body can be used with the MG TA, TB, TC, TDor TF.

TRIUMPH

In 1 9 5 2 when Standard took over the Triumph Company to form the standard-Triumph Motor Company, the Standard Vanguard engine was modified to 2 liters developing 100 BHP and fitted to a Triumph Mayflower chassis to create the TR2 sports car. Since 1 9 5 2 the TR2 has evolved through the TR3 to the TR4 and currently the TR4A with independent rear suspension. A I ~ these cars ha* been fitted with front wheel disc brakes and a l l have an 88" wheelbase.

'The inner-paneling for the JAMAICAN-for-Triumph has been designed to f i t a l l TR1s with two basic models --one for TR3 and TR2 and one for TR4, TR4A, TR4A-IRS, and TR 2 5 0 . Ttlerefore, when a JAMAICAN-for-Triumph is ordered the model must be stated.

3. PREPARING THE CHASSIS

The first step in the building of your new JAMAICAN is to prepare the chassis for the JAMAICAN body. The following tasks to be completed are common for a l l vehicle types.

1. Remove the battery. 2. Drain the gas tank. 3. Remove gas tank f i l ler hose and cap assembly, and tape shut f i l ler neck with masking tape. 4. Remove seats and a l l upholstery. 5. Remove windshield and wiper arms. 6. Remove doors. 7. Remove spare tire. 8. Remove hood-cover engine with tarpaulin or equivalent. 9. Remove deck lid. 10 . Discorlnect al l wirinq to lights srld fue! t ~ v ' r . a d pr~tecbille!y tape thc :.di;.;.ends. 11. Remove headlights and parwturn lights. 1 2 . Remove license I ight-bracket. 13. Remove windshield wiper motor and mechanism. 14 . Remove bumpers. 15 . Remove fenders (most bolts are located inside wheel wells). 16 . Drain engine and radiator of water. 17 . Remove radiator. 1 8 . Remove instruments and panel controls and protectively tape the wire-ends.

For the next steps, turn to the section describing your particular chassis.

AUSTIN-HEALEY

1. Un-bolt relay, fuse block, volt regulator, etc., from firewall and place them down out of the way. 2. Remove gas tank. 3. Remove front bumper brackets and horns. 4. Cut off outer skin at fendu line. 5. Referring to Figure 2A* :

a. Remove rear cross braces (between fender inner panels). b. Remove rear fender inner panels (down to chassis). c. Remove cowl brace (stamped sheetmetal). d. Remove lower door s i l l s and front hinge posts (see detail for cuttirlg side panels). e. Cut 2" off top of firewall. f. Remove body mount brackets and cross brace from front wheel wells. g. Trim 4 " off of outside of wheel wells, parallel with center seams.

6. Remove mounting brackets from radiator and replace 2 " higher on radiator. 7 . While holding radiator in place on chassis mark section of frame cross member that interferes with

lower hose outlet. Cut this section out o f cross member. 8. Bolt radiator i n i ts new position. 9. Trim off a l l protrusions on inside (cockpit side) of firewall above heater duct.

Un-bolt relay, fuse block, volt regulator, etc., from firewall and lace them down out of the way. Remove heater assembly including defrosters. (The blower side oPthe heater box w i l l have to be dropped 1 -1 /4 inches. This i s easi ly done by dis-assembling the box, cutting a wedge out of the side panels, bending new tabs and re-assembl ing the box.) Remove outer skin at fender line. Remove cowl support bracket. Referring to Figure 2Bk : a. Cut front wheel wel l panels just ahead of radiator mounting flanges. b. Un-bolt front bumper support brackets. c. Remove nose section. d. Remove door si l ls, and rocker panels. e. Cut side panels (with hinge posts) straight dowri 2 " back from upper firewall (vertical surface

where relay, fuse block etc., were attached). f. Remove rear fender inner panel cross brace. g. Remove rear fender inner panels down to inner floor surfaces. h. Cut upper firewall straight across from fender panel-to-fender-panel, and trim off a l l pro-

trusions from inside of remaining panel. i. Fabricate radiator mounting flange extensions so that radiator can be mounted down 2" and

forward enough to clear lower hose.

*HEREINAFTER AN ASTERISK FOLLOWING A FIGURE NUMBER REFERS TO THE BLUEPRINTS.

1. Re~liove gas tank. 2. Remove outer skin. 3. Remove a l l hardware from upper firewall. 4. Referring to Figures 2Ctand 2 D * :

a. Remove upper firewall above horizontal surface. b. Remove entire rear fender inner panels and trunk floor. c. Remove rocker panels and side panels (with door hinge posts). d. Removefront fender inner panels 2 " ahead of radiator mounts.

5. Move mounting brackets on radiator up 2 " and re-mount.

The followirig again refers to a l l veliicles, We recomrllend a t this point, t l ~ a t tlle chassis be cleaned of f (steam, gunk etc.) arid painted will1 a rust preventive pairit.

I f you are planning an engine "swap" the instal lat ion of the new engine should be done before mount- ing the body. Seesect ion 9 for V-8 engine installation details.

4 . MOUNTING THE JAMAICAN BODY

We recommend that, prior to mounting the JAMAICAN body on the chassis, a few preparatory steps be completed on the body while access to a l l areas is s t i l l possible. First, with the body upside down, trim the wheel opening flanges back to about 3/4" and sand smooth. Trirn each rocker panel to an equal dimension from the door s i l l and sand smooth. Trim the tai l section return as per Figure 4, and sand smooth. Then, with the body right side up again, cut the windshield and rear window openings to 3/4" from s i l l , cut out the door opening, leaving a 1/2" flange above the fender l ine (window opening, Figure 3E*) and at least 4" flange below the fender I ine (Figure 3 P ) . The lower flange w i l l be trirnmedlater after the body is mounted to the chassis.

We suggest that Uie ta i l section be wired prior to mounting the body while the inside of that area is readily accessible. See Section 6 for wiring details. Be sure that the inner panels are correctly seated on the mounting surfaces of Uie chassis. Do not fasten down the body at this time, but proceed to the next step ---- mounting the doors.

c u t Out and Remove Yy

f- - -- - '%

ect ion Inverted

'IGURE 4

MOLlNTlNG THE DOORS

Before the doors can be mounted, the following steps must be taken:

1. Trim the door edges back to the scribe l ine on the outside skin. 2. Cut the window slot in the top surface as per Figure 5. 3. Attach the door window trim as il lustrated in Figure 3H*.

With these steps completed the doors may now be located in the body and temporaril y held in place with masking tape. Particular attention should be given to the f i t down the rear edge of the door and the area under the wind- shield post. Any mis-alignment along the bottom edge of the door may be corrected when bolting the bod rocker panel (area beneath the door) to the chassis. Now locate the hinges as i n Fibure 3Bk and mark the bolt K o ~ e locations on both the body and the doors. Remove the doors and dr i l l out the holes, using a dr i l l b i t from 1/8" to 1/4" larger than the mounting bolts. The extra large holes w i l l allow adjustment for a perfect fit. I t is advisable to use a backing plate inside the doors for added strength when bolting the hinges to the doors. A plate 1/8" thick and the same shape as the surface of the hinge that bolts to the outside surface of the door should suffice. We have found that a nut-plate for the body-half of the hinges makes installation and adjustment much easier. These plates again may be fabricated of 1/8" steel plate (although 3/16" allows for more threads) approximately the shape of the hinge surface. Dr i l l the bolt holes (undersize) and thread for the mounting bolts. If access to the back of the hinge-mounting surface in the body is not available, cut a 3 " to 4" hole between the upper and lower hinges so that the nut plates may be inserted and secured. The doors may now be installed, with '1," ' - ; * ,y ( : : ; ! o ~ ~ < ~ ? t . , ~ . l ~ : l > : . l \ c c l I" c t 7 9 y

The door latch rnec l~an i s~ r~ , i l lustrated ill F igure 3 P , should be mounted riext. Since such a w ide var iety of latcl ics are avai lable, each w itli i t s own spec i f i c ins ta l la t ion rnetliods, al l attetr~pt w i l l not be ~r~acle here to describe the latc l i instal la ti or^.

After tlie door i r~s ta l l a t i on has been completed, the r n a i ~ ~ body sect ion may be bolted to the chassis (remember to a l ign t l ~ e rocker panels wit11 the doors when attaching these sections).

MOUNTING THE HOOD

Before placing the hood i n pos i t ion on the chassis, t r im the rear edge (at cowl and doors) of the hood back to the scr ibe l ine and trim the wheel opening flanges as per the rear wheel openings. Place the hood on the cowl and block the f ront up unt i l body crease l ines up along the rear fenders, doors and front fenders. Mark the rocker panel overlap and trim for minimurn gap. Wit11 the hood located i n correct pos i t ion make cardboard templates of t l ie hinge brackets. These brackets should be bolted or welded to the main chassis rai ls. See F igure 6 for a typical i r~s ta l la t ion . Be sure to use a t leas t 1-1/2" steel angle or 3 / 1 6 ' ' steel strap for bracket material for strength.

S H I N WITH W A S H E R S T O R A I S E /,/ OR LOWER ( p a r t "0")

A U X I L I A R Y HOLES D R I L L E D FOR fORWARD AND AFT ADJUSTflENT

CONSTRUCTION AND ASSEMBLY FRONT HOOD HINGE

F O R JAMAICAN

5 . INSTALLING THE WINDSHIELD, REAR WINDOW AND DOOR WINDOWS

'The JAMAICAN body is designed s b e c i f i c a ~ ~ ~ to use the Chevrolet Stingray windshield and surround- ing chrome trim. The windshield is supplied as part of the DELUXE ki t . The chrome trim is available from your local Chevrolet dealer (see PARTS L l S T for appropriate part numbers) i f you wish to use i t on your JAMAICAN.

The windshield is installed using the instal lat ion k i t and si l icone rubber sealant l isted in Section 1, under Construction Materials. If chrome trim is to be used, twenty trim-retaining cl ips should be secured in place around Uie edge ot Uie window opening before tlie glass is installed. Small, flat-head wood screws w i l l suff ice to hold the retainers securely. The material in the installation k i t -- "butyl tape" (which has the appearance of a 3 / 8 " diameter rope formed of a tar-l ike substance) -- is now pressed into place along the l i p of the windshield opening. Then, the glass is la id i n place in the opening over the tape and pressure is applied to compress the tape to about 5 0 % of i ts original thickness. Now, the si l icone rubber sealant is squeezed in the gap around the glass --- even on the retaining c l ips --- and the chrome trim is immedi- qtely installed by p r ~ s s i n ? i t into tho c l ips and sealant. Remove the excess sealant as rn*?n -* y " s * l e before i t commences to set. DO NOT DISTURB THE GLASS FOR A T LEAST EIGHT HOURS AFTER INSTALLATION.

The rear window opening is designed expressly to accept the Porsclie 9 1 2 rear window. The DELUXE KIT i n c l x e m a r window glass. The chrome trim is available from your local VW-Porsche dealer ( see PARTS L l S T for numbers). The rear window is installed in the same manner as the windshield. However, i f chrome trim is to be used, the glass should be placed l ight ly on the installation material whi le the sealant is squeezed in the gap and on top edge of the glass. The clirome trim should be placed immediately around the glass and the entire assembly pressed into the instal lat ion material. Again, remove the excess sealant.

The JAMAICAN door window openings are designed to accept VW Karmann Ghia ( 1 9 6 0 - 1 9 6 3 ) door windows. The door inner panels are designed to accomodate the above mentiorled windows and to support the roll-up mechanism --- s l ight ly modified VW Karmann Ghia (see PARTS L l S T for part numbers) --- for raising and lowering the side windows with a standard crank.

Figure 7 shows the guide-track and roll-up mechanism (for the le f t door). The bottom 1" of the guide- track must be cut off to f i t i n the JAMAICAN door and the two positioning p i l la rs should be re-ta ped to 5 / 1 6 - 1 8 to accept the 5 / 1 6 - 1 8 x 2-1/2" f la t head machine screws required to fasten the track to tt!e door inner panel. Dr i l l and counter sink the holes in the door inner panel as i l lustrated in Figure 3A* for the guide-track screws. lnsert the 5/16" f la t head screws in the holes and run lock washers and nuts up the screws on the inside of the panel unt i l they are near the panel. lnsert the guide-track through tlie long slot i n the panel and screw the flathead screws about 1 / 4 " i n the positioning pi l lars.

Re-tap the four tapped holes in the roll-up meclianism,(Figure 7 ) to 1 / 4 - 2 0 . lnsert the mechanism through the large slot in the inner panel, insert the rol ler on the end of the arm into the cross-track on the guide track and bolt to the depress ios in the inner panel with 1 /4 -20x3 /4 I f hex head bolts.

Next, f i t the rubber grommet in the glass holder, f i t the two bolts (be sure to use the original VW bolts) i n the inner holes. lnsert the assembly through the s lo t i n the top of the door and secure to the guide- t rack The closed window may now be adjusted to f i t the window opening by closing the door, cranking up the window and adjusting the guide-track ositioning screws on the inner panel. When in tl ie correct position tighten the nuts on these screws against tRe inner panel and adjust the l im i t adjustment (see Figure 7 ) so that the glass cannot be raised above this position.

6. WIRING AND INSTRUMENTS

This section of the instructions provides tlie ground-rules for completing the basic wiring of your JAMAICAN. In many instances, especially if tlie chassis was not acquired as a wrecked vehicle, the wir ing harness should be intact arid usable; some lengthening or shortening of particular wires may be neces- sary but, in general, the Austin Healey, MG or TR factory-installed wiring harnesses are adequate for tlie JAMAICAN.

In the cases where the original harness has been part ial ly or totally destroyed or a radically different (from the original vehicle) electrical instrument/component layout (e.g., as a result of an "engine-swap") is desired, the following wiring guide sliould be helpful.

A basic wiring harness sliould provide for:

1. Starting 2. Ignition 3. Basic Instrumentation -- te~nperature, o i l pressure (guayes or warning l iglits), fuel level, and

battery/generator corid i t ion. 4. Interior and exterior l ight ing 5. Battery-charging and ground circuits 6. Accessory power and control -- windshield wipers, horn, heater fan, etc.

A t this stage in construction, most items to be wired have been installed; e.g., the starter, the starter solenoid, ignition coi l , o i l pressure arid water temperature senders, battery charging indicator (voltage regulator) and fuel level sender unit are a l l available for wiring. Lights, however, are yet to be installed.

T A I L LIGHTS

AS was mentioned in Section 4 , tlie rear body section should be wired before mounting with plugs for ease of installation. The two common wir ing techniques covering a l l chassis applications are i l lus- trated in Figures 8a,b,c. If your chassis had a single tai l l ight bulb per side, an eight-contact Lucas relay may be found under the hoodand F igu re8b should be used. For a dual tai l l ight bulb installation (no relay), use Figure 8c. We recommend Lhat the original turn signal/brake l ight configuration be retained to simpl i fy the wiring task. In either case, locate and secure the l ight sockets to the body and wire as per the applicable diagram. Dr i l l holes through the inner panels and connect the male end of 4-prong plug or plugs near the center of the rear body panel (on the inside). Be careful to note the function of eachwire being attached to a plug-pin inasmuch as these functions must carry - through to tlie plugs wired on the chassis. HEADLIGHTS AND PARKING LIGHTS

Headlight brackets should be fabricated as shown in Figure 3W and secured to the headlight bucket backing plate. Cut a 7 -1 /8 " diameter hole in the center of the headlight-tunnel and bolt the assembly i n place. Paru tu rn l ights can be installed on sheet-metal brackets located in the gr i l le opening. Remember, when mounting the l ights - -or for Lhat matter, any electrical component --- i n fiberglass, unlike steel bodies, that a SEPARATE GROUND WIRE MUST BE INCORPORATED IN THE WIRING HARNESS in order to com- plete a l l c ircui ts back to the battery "ground" terminal.

INSTRUMENT PANEL WIRING

Your JAMAICAN body is delivered to you wi th a fiberglass dashboard already laminated in place. The dash is designed to u t i l i ze a centralized instrument/control cluster -- this cluster is the hub of the wiring harness and should be carefully planned. The basic instrument/control requirements a r x a t i s f i e d by the following indicators, sw~tches, etc.:

Controls -- 1. Key-operated ignition switch 2. Headlight/parking l ight switch 3. Headlight dimmer switch 4. Accessory control switches, as required.

Indicators -- 1. Fuel level gauge 2. Water temperature gauge or l ight 3. Oi l pressure gauge or l ig l i t 4. Ammeter or charge/discharye warning l ight 5. Headlight high-beam "on" indicating l ight 6. Speedometer (non-electrical).

CHASSIS WIRING

The wiring harness i s divided in two major pieces -- hub-to-front and hub-to-rear. The hub-to- front wires are routed from the hub (instrumenVcontrol cluster) torward to the Firewall arid then t h i - grornmetted hole in the firewall above and to the right of the steering column. Engine instrumentation, ignition and starter solenoid leads end at a terminal block mounted centrally at the top of the engine side of the firewall. Lighting leads continue forward along the frame ra i l and terminate in female connectors which mate with the male connector serving to terminate the in-the-hood wiring. Connection is made at a point on the frame ahead of the front wheel center1 ine.

NOTE: Provide sufficient wire for the male corinector to reach the female connector even with the hood ful ly open.

The hub-to rear harness i s routed from the hub forward to the firewall, along the firewall to the righthand wheel-well, down the firewall to the floor, around the well, under the door-jamb to the rear wheel-well, over the well to the rear of the body.

T H t iiib-TC-;;.EAR tiARNESS CONTAINS:

1. Hub to brake lights -- one #10 wire i n the harness to the RH light, then across Ule rear to the LH light. (DON'T FORGET TO GROUND THE LIGHTS TO THE CHASSIS!) .. -

2. Hub to tail l ights -- one #10 wire routed the same as the brake lights.

3. Fuel gauge to fuel-level sender -- one #16 wire to the tank sender terminal.

4. I f the battery is rear-mounted, the ammeter-to-battery connection is made in the following manner. Connect the battery "hot-side" to the starter solenoid via 12-vol t battery cable run adjacent to a fore-and-aft frame member. Connect the ammeter to the same solenoid terminal via #10 wire run i n the hub-to-front harness.

THE HUB-TO-FRONT HARNESS CONTAINS:

1. The hub to brake l ight switch and return -- two 810 wires to the firewall terminal strip (from the terminal, two #10 wires go to the brake l ight switch mounted on the brake master cylinder or in the forward brake lines depending on the vehicle.] These wires carry battery "hot-side" to the pressure switch and back to the hub for distribution to the rear.

2. Temperature and pressure indicators to appropriate engine mounted senders -- two #16 wires to the terminal block -- from the terminal block two #16 wires to the senders.

3. Ammeter to voltage regulator -- one #10 wire to the terminal block -- one #10 wire from the block to the "armature" terminal on the regulator.

4. Headlight switch to parking lights -- one #10 wire from the hub to the six-pin female con- nector.

5. Headlight switch/dimmer switch (dash mounted) to low beams -- one #10 wire routed as parking l ight wire.

6. Headlight switch/dimmer switch (dash mounted) to high beams --same as low beam.

7. lgnition switch to starter solenoid -- one #10 wire to the terminal block -- one #10 wire from the block down the firewall to the solenoid.

8. lgnition switch to starter solenoid -- one #10 wire to the terminal block -- one #16 wire from the block to the coi l l'BAT.ll,"SW.", etc. terminal.

9. I f the battery is front-mounted, i.e., under the hood, an ammeter-to-battery connection i s re- quired in the hub-to-front harness. Use #10 wire to the terminal block and #lo wire from the block to the battery "hot-side" (U. S. cars use the "+" battery terminal as hot and1'-" terminal for ground, British cars with LUCAS ignition and electrical system use the reverse, i.e., "-" is hot.)

'The items of inslrumentation mentioned above may be ordered from your local Stewart-Warner dealer or directly from Fiberfab. See the parts l i s t for the recommended set Stewart-Warner gauges and senders.

Some " u ~ ~ l ~ a r ~ i e s s e d " conr~ections are required in fie engine compartment. They iricludc:

1. Ignition coi l "DIST", etc. terminal to the distributor -- use # l b wire.

2 . Generator/alternator Field to the voltage regulator -- use # 1 6 wire.

3. Generator/alternator armature to the voltage regulator -- use # 1 0 wire.

4. Battery "hot-side" to the starter solenoid -- use 1 2 - v o l t battery-cable.

5. Battery "ground-side" to grou~id (some point on tile frame close to the battery) -- use 12-vo l t battery-cable.

The preceding material should serve as a guide to the basic w i r i r~g of your JAMAICAN. Ad- ditional items such as horns, direction indicators, tachometers, etc., can be added at your discretion. In general, all additional wir ing can be simply added into the hub-tc-front or hub-to-rear harness with- out incurring any special routing problems.

ROLL-UP WINDOW MECHANISM PARTS

lde~lt i f icat iol l by Voll(swayeti Part Nunibers

L E F T DOOR RIGHT DOOR REGULATOR 1 4 1 8 3 7 501B 1 4 1 837 502B

TRACK ASSEMBLY 1 4 1 8 3 7 5516 1 4 1 837 552B

GLASS HOLDER 1 4 1 837 5 T l k 14; 237 571,?1

WINDOW GLASS GRCMR;lET 1 4 1 837 5 6 5 ~ 1 4 1 837 5 6 5 ~

FIGURE 7

Tap to 5/16-18

7. UPHOLSTERY -- INTERIOR FINISHING

The upholstering of your JAMAICAN is purely a matter of personal taste. You can be as simple or as elaborate as you desire -- austere for the road machine, buff or "posh" for the grarid touring enthusiast.

A t the factory, we use, of course, the JAMAICAN upholstery k i t (available at extra cost). The standard upholstery k i t corrsists, i n part, of automotive-grade carpet cut to f i t tlte floor, f irewall and head- l iner surfaces and bound wi th plast ic, sewn binding to prevent ravell ing. The carpeting is affixed wi th 3M (Copyright, Minnesota Mining and Mar~ufacturing) Tr im Adhesive dispensed from a spray can.

Wood blocks should also be glued into the windshield p i l la rs to provide attachment points for the upholstered pi l lar panels -- again eas i ly constructed of v iny l over cardboard and foam rubber.

I f you have access to a co~nmercial sewirig machine you can make your own carpeting, rugs, etc. Use heavy paper to make a pattern of Uie interior of the car. Transfer this pattern to the carpet (making sure i t is not upsidedown) and cut. Sew on the binding. Spray the surfaces to be covered wi th trim ad- hesive. Instal l the upholstery. Use the same "paper pattern" technique to develop the door panels, wind- shield pi l lar panel, etc. , shapes.

In the area behind the seats (under the rear window) plywood paneling can be inserted between the rear wheel-wells and over the gas tank and spare t i re compartment. Cut a pattern from a piece of corrugated cardboard and transfer this to 1/4" plywood -- use marine plywood and varnish wel l before install ing.

The plywood interior surface can be painted to match the upholstery or covered w i th carpet l i k e the floor and headliner. Chrome skid str ips can be tacked over the carpet, running fore and aft at a 4 " to 5 " spacing -- these strips al low luggage to be eas i ly placed behind the seats without scuff ing the carpet.

Upholstered door panels, avai lable as part of the standard upholstery k i t are attached to the door inner panels wi th plated ph i l l ips head sheet metal screws w i th f in ishing washers.

As a finishing touch, a courtesy l ight can be instal led overhead on the vehicle centerl ine just for- ward of the rear window. Wiring is routed up a windshield post and under the headlirier material. The operating switches are mounted facing up through the door jamb at the very front of the jamb, out of the way of entering and exi t ing feet.

The stock Aust in Heale , M W , or Triumph heating system can be ut i l i zed w i th the JAMAICAN body. New ducts must be cut t lrough the top of the dash to al low defroster air to reach the windshield.

* See chassis preparation for minor modif icat ion to MGA heater box.

8. EXTERIOR FINISH

Tlle ~lrost i rnporta~~t item in t l ~ e arca of exterior finis11 is , of course, tlre 11ai11ti11cl. Fil,crglass is 111ost compatible with acryl ic lacquers. Lacqucrs, also, are the easicst and 111ost tro~rble-frce ill t l ~ e i r app[ ication. They call eve11 be appl icd ill a s l ig l l t l y dusty crrvironlnent -- the dtrst a~ rd spraying imper- fections can be rubbed-out st~bseqirer~t ly. Just fo l low tlte paint i r ~ s t r ~ t c t i o r ~ s atid don' t try sprayirly on cold and/or damp days.

About body surface preparation -- most f iberglass bodies have s l ig l i t inlperfections such as p in lloles or mold~narks. Often they w i l l p ick up a fcw scratclles during shipment. I t is v ir tual ly imposs~ble to avoid this. Body putty and s a ~ l d paper should take care of any body f in ish problems you might have.

We are proud of the finished sllr lace of our bodies. We m e special care and materials around the edges of the body surface to prevent cll i l ls. One of our own AZTECS, wi th over 5 0 , 0 0 0 miles on i t , does not have one body crack irl i t. I t s t i l l has i ts original paint job, too!

Your JAMAICAN body w i l l have a color when you receive i t . I n most instances, t h i s color w i l l be black. This is - riot the finished color. Th is is a special gelcoat your body has been given to achieve a better surface.

Before you paint your JAMAICAN the entire body should be l iq l l t l y sanded wi th k 4 0 0 sandpaper. Tile body is sanded in order to "scuff up" the surface wl l ich i s too s X X G hold paint. Rerrrember to go l ig l l t ly! Then the body should be washed off and wiped witlr Prepsol or some other p a i ~ l t preparation l iqu id to el i~ni t late any o i l or dirt. The body is now ready for primer and paint.

Other Items of Exterior F in ish Are:

WINDSHIELD WIPERS -- The Aust in Healey, MG and TR witldshield wiper actuator systems are almost <dent~cal, one to another. They consist of a 1 2 - v o l t motor dr iv ing a crank which pu l ls and puslles a cable inside a tube. The wiper pivots are mounted on the tube and engage the back and forth rnotion of the cable.

Instal lat ion in the JAMAICAN is simply a matter of nlounting tlre 'pivots in two holes dr i l led through the cowl as shown i n Figure 3F*. Ttre niotor is brought to a convenient mounting locat ion by gently bending the cable-bearing tube unt i l the motor contacts the desired mounting surface.

WEATHERSTRIPPING -- The only place the JAMAICAN may require weatherstripping is around the hood and doors. We suggest, for the hood, using a th in str ip (3/4" wide) of adhesive-backed foam rubber. Typical stripping material is found, for example, i n the Sears catalog bearing # 2 8 A 7 2 2 6 . Apply the stripping after painting. The door weather s t r ip (Figure 3Gf') i s a combination windlace and weatherstrip, a v a i l a b l e r a standard item wi th the ~ ~ p h o l s t e r y ki t , and i s instal led by simply sl ipping over the prepared fiberglass flanges.

9 . V-8 POWER OPTION

Soon after World War II, [lie sports car busit less besari to f lour is l i w i th Llie iritrodoctiori of Ule MG- TC -- and soon after i t s iritroductiori certain owriers ir ievitably wanted more "go". Some enthusiasts welit tile supercliarger/super-t~r~iirig route largely will1 disastrous resul ts -- tlie ~ io tab le exception was the mag- ni f icent (arid very experisive) "o ld 83", arid MG-TC f i t ted wi th al l INTERMECCANICA blower, iritercooler and special body.

Otlier builders resorted to tlie " e ~ i g i ~ i e swap". The M G er~g ine was replaced by [lie ver~erable ,Cord V -8 /60 Substituting engirles -- if sui table c o ~ ~ s t r a i ~ i t s OII e ~ i g i ~ ~ e s ize a ~ i d power were applied -- proved far more satisfactory fliari to "liop-UO" the stock engine.

Today tlie V - 3 / 6 0 IGIS lorlg been superceded by tlie Clievrolet 233 ctl. I r i . V - 8 arid more recent1 y by tile Ford 2 8 9 cu. in. V - 8 "Fair lane e~igir ie".

Any of the veli icles sui table for use wi t l i a JAMAICAN body are also sui table for either of these V-gls. Tlie Aust in Healey 3 0 0 0 series cl lassis i s probably tlie best to use i f etigirie outputs exceedirig

75 DUD a- beirlg cnnq i t l ~ red . We ~*/ould recomrriend, in an;! ca:c, that tlie liorsepower r ~ o t exceed 2 5 0 ~ H P unless the entire frame, dr ive- l ine and suspension are reworked to safely contain the ti iyl ier power.

The best time durirlg the JAMAICAN coristruction to p e r f o r ~ ~ i the engine swap is, obviously, before tile body is mounted. I n tlle course of preparirig the cliassis, rernove the or iginal engine, tlie engine mounts atid [lie transmission and i ls mounts. (Note: Tl ie stock transmission car1 be retained for low power -- under 150 BHP -- instal lat ions a ~ i d if a sui table engine-to-gearbox adapter is available).

Tlie "riew" V - 8 arid gearbox (we used a Warrier T - 1 0 box and a Ford 289 for our Healey-JAMAICAN- Ford, and a Buick Aluniinum V - 8 for our MGA-JAMAICAN-Buick*) are lowered into tlie engine compartment and blocked i n posit ion. New engine and gearbox mounts are now fabricated, f i t ted to Uie eriyine-gearbox inplace, and welded to tlie frame.

Once tlie engine and gearbox are permanently installed, the drive-sliaft car1 be shortened by cutt ing and welding (make certain i t i s straight after welding) arid Llie HURST-shi f ter can be ir istalled.

A high capacity radiator, sucli as tlie Harr ison aluminurri radiator for Corvette, sliould be installed. A surge tank should be mounted wi th tlie f i l le r opening above the level of the cylinder heads.

No signi f icant modification i n w i r i ~ i g sliould be required -- Lhe igni t ion systern remairis 12 -vo l t . Only the o i l pressure and water ternperati~re sending units may be different.

Several notes i n c losing -- a good reference for HURST parts, special engine/gear box mounts, Instruments, etc., i s the "Honest Charley" catalog avai lable from:

H O N E S T C H A R L E Y S P E E D S H O P Honest Street a t North Hiway II Chattanooga, Tennessee 3 7 4 2 1

When acquiring a wrecked vel i ic le for a JAMAICAN arid ari engirie swap is contemplated avoid cars wi th wire wlieels -- choose tlie d isc wlieels for s t r e n g t h n d durabil i ty. -

P L E A S E F E E L F R E E TO CONSULT US! Wlien you are buildirig your JAMAICAN, i f you en- counter some problems outside the scope of these i l lstructions or are having trouble obtaining any of the materials you need, do not hesi tate to contact us. We w i l l be pleased to ass is t you i n any way we can.

" For details concerning tlie V - 8 ir istatlatiori, coriiact otrr factory.

1 0 . THE JAMAICAN-VOLI(SWAGEN

T l ~ e JAMAICAN-VOLKSWAGEN c o ~ ~ v c r s i o ~ i i ~ i s t r t ~ c l i o ~ i s arc set apart fro111 Ll~c I )a la~~ce of 1l1e ~ i ~ a l c r i a l ill tl l is 111a11t1al because of the largc I IUI I I~JC~ of II I I~CI~IC proccd~~rcs i ~ ~ v o l v c d ill COIIIJ)ICL~II~ l l i is rear-cngi~icd variation. Sections 1 , 2 a~icl 4 t l i r o ~ ~ g l i 3 arc appl ica l~ le to your VW-based project. Sec t io~ i 3, I~owevcr, is supercedetl by t l ~ e f o l l o w i ~ ~ g ~ ~ ~ a t c r i a l .

REMOVING THE VOLI<SWAGEN BODY

Before you start to cl~ll)olt tllc body, rerliove the front and rear seats, discorir~ect and relllove tlie battery slid drain tlie gas tank. Next, relllove t l ~ c le f t front t i re/wl~eel ill order to urlbolt tlie steering shaft by rerni,vi~iy two bolts fro111 tile steering shaft u ~ ~ i v c r s a l joint. Now d i s c o ~ ~ ~ ~ c c t the Iiorn wirc.

Now discon~iect the I I I ~ I ~ L I ~ ~ c l ~ o k e cable or tlie wire from tlie electr ical ly operated clioke. Discon~iect tlic wires (to tlie coi l a ~ ~ d voltaye regt~lator) and ~ L i e l L l u i u , caLI? fro;,, ~IIC ~ ~ : ; i ~ i c .

Remove tlie choke froni t l ~ e dasliboarrl (110 dasliboard co~i t ro l exists for tlie electr ical ly/ t l~er~nostat ical ly operated c l~oke) a ~ i d pull tlie cable tlirougli to remove i t . Discon~iect t l ~ e gas l i ~ ~ e s to the gas tank and remove tile tank by llnbolting (see Figure 9 ) a ~ ~ d l i f t i ~ i g i t up and out. Don't forget tlie reserve fuel switch-over valve in t l ~ e cockpit.

You are now ready to unbolt t l ~ e body. F i rs t , relnove tlie bolts located alorig the outside edges of the llliderside of the floorpall (see Figure 9 ) . Next, relnove the several bolts r e l ~ ~ a i n i ~ i g at tlie front underside of tile floorpan -- just inside tlie front wheel-wells.

Remove tlie four bolts exposed w l ~ e l i the rear seat was taken out. F ina l ly , remove the rear tires/wlieels arid unbolt the body bolts ill tlie wlieel-wells. SAVE THESE BOLTS!

The body s l~ould now be free to be l i f ted off v ia block and tackle, c l~ain-hoist , or yourself and "several strong and wi l l ing helpers." CAUTION : Tlie Volkswager~ llody is extreniely Iieavy! I t is because of this weight loss, incidently, that you rnay expect better-t l iarl-Volkswagen pertortr~arice 111 your completed JAMAICAN-VW.

Care should be exercised when l i f t ing off tlie Volkswagen body in order to preserve the body-to-floorpan rubber seal. I t can be used to "weatherstrip" your new JAMAICAN body.

I t is advisable to save a l l tlie undamaged parts such as tlie steering colutnn and wlieel, gas tank, in- struments, etc., inasmuch as these items can be used to complete your JAMAICAN.

INSTALLING THE FRAME RAILS

The frame rai ls are installed next. Remove the dust covers (4 bolts each) from over tlie elids of the rear torsion bars (covers on early chassis f i t around the end of Llie torsi011 bar leavirig i t exposed, while covers on late chassis completely cover tlie end of the bar).

Modify the dust cover as shown i n Figure 10 and replace then on the floorpan with the upper two bolts (don't forget to put the rubber "dougllnuts" back under the covers.) Bolt the end-plate of tlie frame ra i ls to the floorpan over the dust covers using the bottom two dust cover retaining,bolts -- leave the bolts loose. L i f t the front end of tlie frame ra i l and secure i t under tlie lower, front tors1011 bar housing (tube) using the U-bolts provided with the frame rai ls. Posit ion tlie U-bolts about 13 inches either side of tlie floorpan centerline -- tigliteri a l l bolts. Secure tlie edge of the floorpan to tlie ra i ls by d r i l l i ~ i g tlirough tlie 'pan Into the 'rails and fas te r~ i~ ig with large sheet-metal screws.

FIGURE 1 0

REPOSITIONING THE COCKPIT CONTROLS

With the floorpan supported by the frame rails, the central tunnel of the floorpan can be cut and "rear- ranged" in order to relocate the pedals and gearshift. Referring to Figure 9 -- three fu l l sections are cut from the tunnel and replaced as shown. The cutting can be accomplished using a sabre-saw or an oxy- acetylene cutter. Cuts should be made along the side of tlie tunnel as close to the floor as possible -- cuts up the sides should be perpendicular to the floor. Care should be taken to cut only the tunnel, not the tubes and cables running within the tunnel.

Figure 11 shows the reconfigured VW 'pan ready for the JAMAICAN body. For the pedals to operate i n their "new" position the clutch and accelerator cables must be shortened by cutting-off 14 1/2 inches and reswaging the end fitt ings to the cut ends. The tubing surrounding the accelerator cable i s puslled back inside the tunnel and .cut-off flush a t the point it exists the rear of the tunnel. The pedal pivot support tab is re-bolted to the pan through a new hole dril led in the 'pan after the pivot is securely i n i ts new position.

Repositioning the steering column and wheel is accomplished by lowering (reducing the angle between the 'pan and the column) and lengthening the steering column/shaft. The required lowering is quite simple. The VW steering box is only clamped on the upper front torsion bar housing. I t can be rotated on the housing just by loosening the clamps. With the clamps loosened, the steering box should be rotated such that the steering linkage just clears the "hump" in the center of the floorpan when the wheels are turned from lock-to-lock. (Lowering the steering box alters the toe-in adjustment of the steering geometry. Proper toe-in is reestab- lished by adjusting the tie-rods until the fronts of the front tires are about 1/8" closer together than the backs -- refer to Figure 12. Make sure the adjustment is divided equally between the tie-rods).

FIGURE 1 2

A simple metllod of lengtlienirig the stecring shaft the required 1 4 inches is to insert the extension, sliown in Figure 13, between the steeri l~g box and tlie steering shaFt. Tlie order of assernbly o f stecring components in a stock VW is: steering box, flexible rubber disc, "TI'-flange, stecring shaft. Tlie revised order of assembly For the JAMAICAN/VW is: steering box, flexible rubber disc, 14'' extension, Flexible rubber disc, "TIL-flange, steering shaft.

.

+ 3' --I FIGURE 13

MOUNTING THE REAR HANGERS

The final step in preparing tlie floorpan i s to mount the rear hangers For the ta i l section of the GT-12 body. Figure 1 4 shows both hangers i n place on the mounts formerly used to secure the Volkswagen body. When the Fiberglass tai l section i s installed, shims (washers) may have to be placed under the front, rear or both hanger-mounting feet (see Figure 1 4 ) to precisely al ign the ta i l section with the main body section.

I FIGURE 14