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Fiberfab Aztec 7 Assembly Manual

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  • Page 3 Table of Contents Construction Material, Tools and Power Tools Selecting a VW To Use For Your Aztec 7 Removing The VW Body Disassembling The VW Chassis Preparation Softening Front Suspension Decambering Rear Suspension Installing Tail Section Supports Installing Heater Vent Tubing...
  • Page 4 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 Reservoir Installing the Hood Installing Locking Hood Hold-down Pins Gas Tank Installation Painting...
  • Page 5 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.
  • Page 6 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...
  • Page 7 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.

  • Page 8: Chassis Preparation

    CHASSIS PREPARATION Refer 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. Remove battery brackets from the floor pan with a cold chisel. 3.
  • Page 9 Figure 4a VW Chassis Figure 4b Removing Seat Rail...
  • Page 10 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 Required Wrenches Screwdrivers Scribe Welding torch -Optional Refer to Figure 5a and Figure 5b 1.
  • Page 11 DECAMBERING REAR SUSPENSION Tools Required Jack Stands Wrenches Refer to Figure 5a and Figure 5b 1. Place the rear wheels of the VW chassis on jack stands or blocks, and remove the rear wheels. 2. Unbolt the four bolts that hold the torsion bar dust cover cap, and the three bolts that hold the spring plate to the rear axle.
  • Page 12 INSTALLING TAIL SECTION SUPPORTS Tools Required 2 - 9/16 inch wrenches or socket set 2 - ¾ inch wrenches or socket set Parts Requires Ff #Z763 1 set rear body supports and #Z762 hinges Ff #X137 chassis paint Ff #1 bolt pack Refer to Figure 6 Install rear tail section supports to chassis.
  • Page 13 INSTALLING HEATER VENT TUBING Tools Required Knife Caulking Gun Parts Required Ff #X180 heater tubing Ff #MX193 Silicone Refer to Figure 7 Cut two lengths of heater tubing 24 inches long each. Apply a bead of silicone all the way around the tube approximately 1 inch from the end as illustrated in Figure 7.
  • Page 14 MOUNTING THE VOLTAGE REGULATOR Tools Required Electric Drill and Drill Bits Screwdriver Wire Cutter/Stripper Parts Required 14 Gauge Wire 12 Gauge Wire Wire Terminals #10 X ½ inch Metal Screws Refer to Figure 9 Locate the regulator on the fan shroud directly above the generator/alternator flange. Mark and drill two holes and fasten the regulator to the shroud using #10 X1.2 inch sheet metal screws.
  • Page 15 Refer to Figures 8, 10 and 11 Remove the VW oil pressure-sending unit. This is located at the base of the distributor. Install the Fiberfab oil pressure-sending unit in the same location. The location of the sending unit is shown in Figure 8.
  • Page 16 Figure 10 Oil Temperature Sending Unit Figure 11 Air Cleaner...

  • Page 17: Installing The Center Console

    INSTALLING THE CENTER CONSOLE Tools Required Drill 3/8 inch Drill Bit Jigsaw 3/8 inch Socket Set Parts Required Ff #Z411 Floor Console Ff #X120 Shifter Refer to Figures 12, 13 and 14 1. Cut the openings in the console for the shifter and hand brake lever. Use the plate in the shifter kit for the shifter opening pattern.
  • Page 18 Figure 13 Installing Lower Console Figure 14 Installing Shifter...

  • Page 19: Installing Of Speedometer Cable

    INSTALLING OF SPEEDOMETER CABLE Tools Required Needle Nose Pliers Parts Required Ff #X187 Speedometer Cable Refer to Figure 15 Push the speedometer cable through the left front spindle and hub dust cover. Insert cotter pin through cable end. Figure 15A Placement of Speedometer Cable Through Wheel Figure 15B Detail: Cable End and Cotter Pin –...

  • Page 20: Main Body Preparation

    MAIN BODY PREPARATION 1. Cutting the Windshield Opening Tools Required 40 Grit Sandpaper Tape Drill 3/8 inch Drill Bit Jigsaw Refer to Figure 16 Cut the opening in the front of the main body for the windshield. Start the cut by drilling a 3/8-inch hole and insert saw blade in this hole.
  • Page 21 Figure 17 Rear Window Opening 3. Cutting the Door Openings Tools Required 40 Grit Sandpaper Tape Drill 3/8 inch Drill Bit Jigsaw Refer to Figure 18. Cut the opening on each side of the main body section. Sand to the scribed lines. Figure 18 Door Opening...
  • Page 22 4. Defroster Installation Tools Required Drill 5/16 inch Drill Bit Tape 2 – 7/8 inch wrenches or sockets Parts Required Ff #X14111 Defroster Bolt Kit #2 Refer to Figures 19 and 20 Measure and drill holes as shown in Figure 19 using a 5/16-inch drill bit. Install defroster motor on the inside of the car.
  • Page 23 Figure 20 Detail: Defroster Installation Figure 21 Motor Location Top View...
  • Page 24 5. Windshield Wiper Motor Installation Tools Required Drill 5/16 inch Drill Bit 5/8 inch Drill Bit 2 – 7/16 inch Wrenches Parts Required Ff #Z767 Power Motor Ff #Z782 Pivot Shaft Ff #Z783 Drive Arm Bolt Kit #3 Refer to Figures 21 and 22 Measure and mark the windshield cowl for holes to be drilled to mount the wiper motor as shown in Figure 21.
  • Page 25 6. Drill Holes for Wiring Harness Tools Required Drill 1-1/2 inch hole saw Refer to Figures 23 and 24 Use a 1-1/2 inch holes saw to drill holes in the firewall and inner liner as shown in Figures 23 and 24. Figure 23 Wiring Harness –...
  • Page 26 Figure 24 Wiring Harness – Drill Hole Location Figure 25 Dashboard and Overhead Console...
  • Page 27 7. Preparation of Dash and Overhead Console Tools Required 40 and 120 Grit Sandpaper Jigsaw Flat Black Paint Medium Steel Wool Scissors 1-1/2 inch brush Drill ¼ inch Drill Bit 3 inch Hole Saw 2-1/6 inch Hole Saw 1-1/2 inch Hole Saw ¾...
  • Page 28 Use a brush to apply contact cement to the back of the veneer and faces of the cash and console. Follow instructions on the can of cement and apply the veneer to the cash and console. Mark the veneer for holes to be drilled for gauges and switches mounted in the dash and console using the templates.
  • Page 29 Figure 31A Dashboard Layout for Gauges Figure 31B Overhead Console Layout...
  • Page 30 9. Installation of Dashboard Tools Required Drill 3/16 inch Drill Bit Philips Screwdriver 3/8 inch Wrench Pop River Gun Parts Required Bolt Kit #4 Ff #M5604B Wiring Harness Clamp Refer to Figure 32 Place dash under the windshield opening and drill through the body and dash at the dimples using a 3/16-inch drill bit as shown in Figure 32.
  • Page 31 Courtesy Lights Tools Required Electric Drill 4 inch Drill Bit Tape Measure 2 – 7/16 inch Wrenches Parts Required Ff #Z777 Courtesy Light Plates Ff #Z758 Courtesy Lights Bolt Kit #4 To install courtesy lights, position mounting plate 4 inches in from each end of the underside of the dash flange, with the hole for the light towards the firewall at the front of the main body.
  • Page 32 10. Routing the Main Body Wiring Tools Required Drill 3/16 drill bit Pop rivet gun Parts Requires Ff #M560E Fuse Block Ff Bolt Kit #5, #6 Refer to figure 33, 34 and 35 Run the wiring for the overhead console in the windshield ‘A’ pillar and tape the harness in place as shown in Figure 33.
  • Page 33 Figure 33B. Detail Wiring Harness Clamps to Reinforcing Pipe Figure 34 Wiring Harness Routing...
  • Page 34 Figure 35 Fuse Box Installation...
  • Page 35 INSTALLING THE MAIN BODY ON THE FLOOR PAN Tools Required Caulking gun Drill 3/8 drill bit ¼ drill bit 1/8 drill bit 3/16 drill bit Socket Set 9/16 wrench 7/16 wrench Phillips Screwdriver Pop Rivet Gun Jigsaw 40 grit Sandpaper 1-1/2 paintbrush 5/16 drill bit Screwdriver...
  • Page 36 Figure 37 Mounting Main Body to Chassis. Figure 38 Detail: Main Body to Chassis...
  • Page 37 Figure 39 Carpeting Beneath Lower Console. Bolt the center console to the dash as shown in Figure 40. Mark the console as shown in Figure 41. Drill through the console and chassis tunnel with a 1/8-drill bit. Fasten the console to the tunnel using bolt kit #9 in the holes drilled. Cut the flanges on the battery box and luggage compartment as shown in Figure 42 and sand the edges smooth.
  • Page 38 Figure 41 Center Console to VW Floor Pan Location of Bolt Holes Figure 42 Position Luggage Box on Main Body...
  • Page 39 Figure 43 Luggage Box Lid and Hinge Attachment Figure 44 Mounting Lid to Main Body...
  • Page 40 THE GULL WING DOORS 1. Preparing the Gull-Wing Doors. Tools Required Assorted files 40, 80 and 120 grit sandpaper Putty Knife Parts Required Body Filler Refer to Figure 45 File and sand the inside of the door edges to about 3/8 thick as shown in figure 45. Fill low spots with body filler if necessary.
  • Page 41 2. Cutting the Side Window Openings Tools Required Drill 3/8 drill bit Jigsaw Tape 40 and 80 grit sandpaper Refer to Figure 45 Drill a 3/8 hole in the area where the side glass will be installed. Use the hole for starting the cut with the jigsaw. Cut the opening out and sand to the scribe line as shown.
  • Page 42 3. Preparing the Door for Latches Tools Required Drill 6 Inch Hole saw or Jigsaw Tape ¼ Drill bit Rattail file Scissors Medium Steal Wool Parts Required Ff #Z731 Door Latch Plate Ff #Z787 and #Z725 Door Lock Kit Ff #X137 Flat Black Paint Refer to Figures 46 through 49 On the inside of the door measure 8-1/4 left and right of the center of the door latch indent and 4-1/2 down from the top of the door flange.
  • Page 43 On the door latch inset, measure 1-1/2 inches from each corner and drill two 5/16 inch holes. Use a rattail file to open a notch between the holes as shown in Figure 48A. Figure 48A Notching Door Latch Inset The ¼ inch hole drilled though the outside door skin earlier is for the door lock cylinder. A pattern of the lock cylinder should be made and traced around the ¼...
  • Page 44 Use medium steel wool to sand the door flange and window opening. Paint these areas with the flat black paint as shown in Figure 49. Figure 49A Preparing Door and Window Flanges...
  • Page 45 4. Locating the Door Hinges Tools Required 1-1/2 Masking Tape Refer to Figure 49B Place the door in the main body door opening and align the top of the door with the roof of the main body and the lower edges of the door with the body. When you are satisfied with the door alignment, tape the door in place. Measure 3 inches from each outer edge of the door roof and continue the line onto the main body roof as shown in Figure 49B Figure 49B Location of Door Hinges...
  • Page 46 5. Mounting the Door Hinges Tools Required Drill 3/16 inch Drill Bit Tape Philips Screwdriver 3/8 inch Wrench 40 and 80 grit Sandpaper Parts Required Ff #M553 Hinges Bolt Kit #12 Refer to Figures 50A, 50B and 51 Position the holes in the door hinge over the lines drawn on the roof and the door top. Center the hinge pins over the space between the door top and the main body roof.
  • Page 47 Bolt the doors to the main body through the hinges with bolts and huts in bolt kit #12 as in Figure 50B. Figure 50B Mounting Door Hinges Open and close the doors to be certain they operate freely. It may be necessary to sand the outer door flange as shown in Figure 51.
  • Page 48 6. Installing the Door Assist Cylinders Tools Required Drill 3/16 inch drill bit Philips Screwdriver 3/8 inch wrench 1-1/2 inch masking tape ¼ inch X 20 Tap and Handle Parts Required Ff #Z772 Cylinder Brackets (4) Ff #Z729 Assist Cylinder Ball Stud (8) Ff #Z727 Door Assist Cylinders (4) Ff #Z728 Assist Cylinder Safety Clip Bolt Kits #13 and #14...
  • Page 49 Using bolt kit #13, fasten the brackets to the inside of the flanges as in Figure 52B. Put strips of 1-1/2 inch masking tape on the door ceiling next to the door flange. Close the door and draw a line on the tape along the main body flange by reaching through the window opening as shown in Figure 52C.
  • Page 50 Figure 53A Position Bracket on Doors. Figure 53B Detail: Mounting Assist Cylinder Brackets to Door. Figure 53C Assist Cylinder Bracket Installed...
  • Page 51 Figure 53D Detail: Assist Cylinder Ball Stud Figure 53E Detail: Ball Stud and Safety Clip...
  • Page 52 7. Installing the Door Latches Tools Required 7/16 inch wrench Socket Set Parts Required Ff #Z731 Latch Plate Ff #Z732 Remote Arm Ff #Z726 Latch Bolt Kit #15 Refer to Figure 54 Attach the door latch to the latch plate with bolts in bolt kit #15. Bolt the plate to the door being certain the pin from the outside lock cylinder fits in the slot in the latch as shown in Figure 54.
  • Page 53 8. Fitting the Striker Plate Tools Required Drill ¼ inch drill bit Jigsaw Philips Screwdriver Socket Set Parts Required Ff #Z730 Striker Plates Bolt Kit #16 Refer to Figure 55 Locate the striker plate on the raised area of the doorjamb. Use the striker as a template to mark for bolt holes and the portion of the door jamb to be removed under the striker plate.
  • Page 54 9. Installing the Door Stops Tools Required Drill 5/16 inch drill bit Two ½ inch wrenches Parts Required Ff #Z755 Rubber Adjustment Stops Bolt Kit #17 Refer to Figure 56 Using the 5/16-inch drill bit, drill 4 holes in each door jamb at the points indicated in Figure 56. Install the doorstops so they fit snugly on the stops using bolt kit #17 Figure 56 Location of the Door Stops.
  • Page 55 10. Preparing the Door for the Installation of the Side Glass Tools Required Drill 5/16-inch drill bit Rotary File or Rattail File Refer to Figures 57 and 58 Place the glass in position of the window flange and center it in the opening. Mark the center line of each hole in the glass on the door ABOVE the window.
  • Page 56 11. Installing the Side Windows Tools Required 7/16 inch wrench Standard and Philips Screwdrivers Parts Required Ff #Z741 Side Glass Ff #Z745 Side Glass Latch and Hinge Kit Bolt Kit #18 Refer to Figure 59 and 60 Install all hardware on the side glass as shown in Figure 59. Install the side glass in the window opening using bolt kit #18.
  • Page 57 INSTALLING THE HEADLIGHT DIMMER SWITCH Tools Required Drill ¼ inch drill bit Socket Set 5/16-inch wrench Parts Required Ff #X131 Dimmer Switch Bolt Kit #20 Refer to Figures 63 and 64 Locate the position for the dimmer switch according to Figure 63 and drill at this point using a 1 inch hole saw. Insert the dimmer switch through the firewall and use the mounting plate of the switch to scribe the two mounting holes onto the firewall.
  • Page 58 Figure 64 Detail: Mounting Dimmer Switch to Fire Wall...
  • Page 59 DETAILING THE INTERIOR 1. Installing Headliner Tools Required 1-1/2 inch paint brush Trim Knife Parts Required Ff #MX194 Contact Cement Ff #Z759L Headliner Refer to Figures 65 through 70 Paint contact cement on headliner where headliner will meet the raised areas of the inner liner as shown in Figure 66.
  • Page 60 Figure 66 Headliner and Contact Cement Figure 67 Contact Cement to Inner Liner...
  • Page 61 Allow the cement to dry and then press the headliner into place and pull the overhead wiring harness through the slot cut. The edges of the headliner should be wrapped around the edges of the fiberglass as shown in Figure 68. Paint cement on the windshield pillars.
  • Page 62 Figure 70 Headliner to Windshield Pillar...
  • Page 63 2. Installing the Firewall Upholstery Tools Required Trim Knife 1-1/2 inch paintbrush Parts Required Ff #MX194 Contact Cement Ff #Z759A Rear Firewall Upholstery Refer to Figure 71 Apply cement to rear firewall and upholstery and allow to dry. Press the upholstery into place as in Figure 71. Figure 71 Rear Firewall Upholstery...
  • Page 64 3. Installing Upholstery on Front Firewall Tools Required Trim Knife 1-1/2 inch Paint Brush Parts Required Ff #MX194 Contact Cement Ff #Z759B Front Wall Upholstery (Note: there are 3 pieces in this group) Refer to Figure 72 Paint cement on the front firewall and all three pieces of upholstery and let the cement dry. Install the center section first and then the sides.
  • Page 65 4. Installing Side Panels Tools Required 1-1/2 inch paint brush Parts Required Ff #MX194 Contact Cement Ff #Z759C Side Panels Refer to Figure 73 Apply cement to fiberglass where side panels will be installed. Paint cement on the side panels. Allow cement to dry and press the panels into place.
  • Page 66 5. Installing Door Flange Trim Tools Required Drill 1/16 inch Drill Bit Philips Screwdriver Hacksaw Fine Tooth File Parts Required Ff #Z707 Flange Trim Bolt Kit #21 Refer to Figure 74 Measure the doorjamb and cut a length of trim to fit. Smooth the edges with a fine file. Bend the trim as necessary to fit.
  • Page 67 6. Upholstering Center Console Tools Required Trim Knife 1-1/2 inch Paint Brush Drill 1/16 inch Drill Bit Philips Screwdriver Parts Required Ff #Z759D Center Console Upholstery Ff #MX194 Contact Cement Bolt Kit #22 Refer to Figure 75 Apply contact cement to sides of console and material that covers the side. Press material in place after the cement has dried.
  • Page 68 7. Installing Shifter Boot Tools Required Drill 1/8 inch Drill Bit Screwdriver Parts Required Ff #X120 Shifter Boot Refer to Figure 76 Install the shifter boot over the lever. Use the cover as a template for drilling 4 1/8 inch holes as shown in Figure 76.
  • Page 69 Install the number cover in the same manner. Note: You may not want to cement the number cover in place yet as access to chassis numbers may be necessary to register your completed Aztec 7. Figure 77 Installing Floor Mats...
  • Page 70 9. Installing Door Panels Tools Required Pliers Drill 1/16 inch Drill Bit Philips Screwdriver Parts Required Ff #Z759F Door Panels Ff #Z759G Door Panel Pull straps Bolt Kit #23 Refer to Figures 78, 79 and 80 Attach the pull strap to the inner panel of the door with 4 screws from bolt kit #23, as in Figure 78. Fasten the ‘S’ hook to the latch arm as shown and squeeze the hook closed with the pliers.
  • Page 71 Figure 79 Door Pull Strap to Latch Arm Figure 80 Attaching Door Panel...
  • Page 72 10. Installing Heater Vents Tools Required Drill 2 inch Hole Saw Socket Set Parts Required Ff #X181 Heater Vent Parts Refer to Figures 83 and 84 Measure the outside of the rear firewall and cut 2-inch holes as indicated by Figure 83. Install the heater vent outlets as shown in Figure 84.
  • Page 73 Figure 84 Installing Heater Vents and Heater Hose...
  • Page 74 11. Installing the Overhead Console Parts Required Drill 3/16 inch Drill Bit 1/8 inch Drill Bit Philips Screwdriver Parts Required Bolt Kit #25 Refer to Figure 85 Connect the overhead wiring harness to the overhead console per the instructions with the wiring kit. Drill four 3/16-inch holes as shown in Figure 85.
  • Page 75 12. Installing the Steering Shaft Tools Required Drill 5/16 inch Drill Bit ¼ inch Drill Bit 2 inch Hole Saw Jigsaw Socket Set Pliers Screwdriver ½ inch wrench Flat File String Parts Required Bolt Kit #26 Ff #Z785 Steering Column Upper Support Ff #Z786 Steering Column Lower Support VW Steering Column Refer to Figures 86 through 94...
  • Page 76 Figure 87 Steering Column and Shaft Slide the steering shaft through the dash and the flange. Slip the column housing over the steering shaft through the hole in the dash and into the flange. Refit the column on the steering shaft. Connect the steering shaft to the steering box as in Figure 88.
  • Page 77 Figure 89 Steering Column Flange Figure 90 Steering Column Support...
  • Page 78 13. Installing the Steering Wheel Tools Required Socket Set Parts Required Horn Wire Ff #X157 Adapter Kit Ff #X155 Steering Wheel Refer to the Instructions included with the steering column adapter, steering wheel kit and Figures 93 and 94 Figure 93 Steering Column Adaptors and Steering Wheel...
  • Page 79 14. missing...
  • Page 80 15. Installing the Rear Glass Tools Required Knife Silicone Lubricant Dull Screwdriver Parts Required Ff #Z743 Rubber Glass Gasket Ff #Z742 Rear Window Refer to Figures 96, 97 and 98 Trim the rear section of the headliner material flush with the edge of the fiberglass as shown in Figure 96. Figure 96 Rear Glass Gasket Installation Place the rubber gasket in the window opening starting at one side and running the gasket all the way around.
  • Page 81 16. Installing the Windshield Tools Required Knife ¾ inch Masking Tape Car Wax Caulking Gun Parts Required Ff #MX193 Silicone Ff #X100 Butyl Tape Ff #Z740 Windshield Ff #X137 Paint Trim the headliner back to approximately ½ inch from the edge of the windshield opening as shown in Figure 99. Figure 99 Headliner Over Windshield Opening Flange Mask the edge of the windshield inside to allow approximately 1 inch of exposed glass along the perimeter of the windshield.
  • Page 82 Apply commercial car wax to the outside of the windshield about 3 inches around the edge. Do not buff out the wax. Tape the main body around the windshield area with ¾ inch tape as shown in Figure 101. Press butyl tape around the edge of the windshield opening as in Figure 101.
  • Page 83 Figure 103 Detail: Smooth Silicone Along Edge of Windshield...
  • Page 84 17. Installing the Seats Tools Required Drill 5/16 inch Drill Bit Socket Set ½ inch Wrench Chalk 1-1/2 inch Paint Brush 40 Grit Sandpaper Parts Required Ff #X127 Seat Rails Ff #Z781 Seat Brackets Ff #Z759H Seat Back Rugs Ff #Z759I Seat Covers Ff #MX194 Contact Cement Bolt Kit #27 Bolt Kit #28...
  • Page 85 Figure 105 Location of Seat Brackets Under Seats Figure 106 shows the seat brackets. The four holes in the vertical part are for adjustment of the seat height. Bolt the bracket to each end of the seat rail through the top hole in the bracket. Use bolt kit #27. The ‘L’ of the bracket should face the center of the seat.
  • Page 86 Figure 107 Seat Back Upholstery Figure 108 Installing Seat Covers...
  • Page 87 Set the lockable seat rail in the center position and place the seats in the car as shown in Figure 109. Look at the seat bottom. It must be level from the side to side and should be slightly raised in the front. Adjust as necessary using the vertical holes in the brackets.
  • Page 88 Figure 110 Detail: Seat Bracket to Chassis...

  • Page 89: Tail Section

    TAIL SECTION Tools Required Drill ¼ inch Drill Bit 1/16 inch Drill Bit 3 inch Hole Saw Jigsaw Tape Phillips Screwdriver Socket Set Carbide Router Bit 40 and 80 Grit Sandpaper Assorted Files Parts Required Ff #Z736 Taillights Ff #Z737 Red Side Marker Lights Ff #Z738 Four Light Brackets Bolt Kit #29 Bolt Kit #30...
  • Page 90 Figure 112 Locating Taillights The rear panel will meet the inner panels at right angles on each side of the car. The inner panels must have a 3- inch notch cut in them, as shown in Figure 113, to allow for the fittings of the light assembly. Figure 113 Inner Panel Notch –...
  • Page 91 Place the taillight units in the holes and put the mounting brackets over the bolts in the light units. Secure the taillights in place with bolt kit #29 and in Figure 114. Figure 114 Installing Taillights...
  • Page 93 Measure and mark the center for the side marker lights using dimensions shown in Figure 115. Place the light gasket over the center mark and scribe the outline for the lights and cut the hole open. Mark the location of the mounting studs on the tail section and drill them with a 1/8-inch drill bit.
  • Page 94 Mark the rear panel as shown in Figure 117 and cut 3-inch holes at these points. This will give access for bolting the bumper in place and wiring. Scribe two lines, ¾ inch and 5 inches from the bottom edge of the rear panel. Mark four points along each line near the 3-inch access holes as shown in Figure 118.
  • Page 95 2. Installing the Rear Bumper Tools Required Drill ¼ inch Drill Bit Hole Saw 7/16 inch Wrench Socket Set 120 Grit Sandpaper Two 6-inch ‘C’ Clamps Parts Required Bolt Kit #31 and #32 Ff #Z758 Two License Plate Lights Two Steel Washers Refer to Figures 119 to 122 Sand the bumper flanges smooth with 120 grit sandpaper.
  • Page 96 Position the bumper on the rear panel with the lower edge of the bumper even with the lower edge of the body. Clamp the bumper to the body or have an assistant hold the bumper in place as shown in Figure 121 From inside the car, drill through the eight bumper mounting holes into the bumper flanges with ¼...
  • Page 97 3. Installing the Tail Section Tools Required Masking Tape Drill ¼ inch Drill Bit 3/8 inch Drill Bit 9/16 inch Wrench Socket Set 1-5/8 inch Hole Saw Rattail File 80 Grit Sandpaper Two ‘C’ Clamps Parts Required Ff #M560G Wire Ties from Wiring Kit Bolt Kit #33 Ff Z766 Two Tail Section Adjusters Refer to Figures 123 through 128...
  • Page 98 Place the tail section on the chassis. The ends of the rear support brackets should fit on the inside of the inner panel as shown in Figure 125. The front of the tail section should meet with the doors at th top of the main body. The wheel well flanges should aligh with those on the main body.
  • Page 99 Clamp the body and tail section together at the wheel wells with ‘C’ clamps. Using the previously drilled hole in the main body flange as a guide, reach up through the fender well and drill a ¼ inch hole in the matching tail section flange.
  • Page 100 5. Tail Section Holding Pins Tools Required Masking Tape Drill 1/8 inch Drill Bit ¼ inch Drill Bit 5/8 inch Drill Bit Rattail File Screwdriver Crescent Wrench Parts Required Ff #X113 Tail Section Hold Down Pins Ff #Z766 Tail Section Adjusters Bolt Kits #34 and #35 Refer to Figures 129 through 133 Mark the points for the hold-down pins as shown in Figure 129 and drill these marks with a ¼...
  • Page 101 Figure 130 Installing the Holding Pins Figure 131 Installing Holding Pins – Chrome Plate...
  • Page 102 Install the tail section adjusters by drilling four 5/16-inch holes in the main body as the points shown in Figure 132. Install the adjusters as shown in Figure 133. Turn the adjusters up or down until the roof of the main body and the tail section are in alignment.
  • Page 103 6. Tail Section Detailing Tools Required 1-1/2 inch paint brush Wire Crimping Tool Knife Parts Required Ff #M560AB Wiring Clamps Ff #Z774 Brake Light Sockets Ff #Z775 Turn Signal Sockets Ff #Z776 Backup Light Sockets Refer to Figure 134 Install the rear edge of the headliner that was left loose when interior was installed Figure 134 shows the lights in the tail section to be wired.
  • Page 104 WEATHER STRIPPING 1. Weather Stripping the Door Jambs Tools Required Phillips Screwdriver Knife Parts Required Ff #Z739 Door Opening Weather Strip Ff #MX200 Trim Adhesive Refer to Figures 135 to 137 Remove the metal trim installed earlier. Cut the upholstery that was previously folded over the fiberglass edge allowing about 3/16 inch to remain on the edge as shown in Figure 135.
  • Page 105 Figure 137 Weather-stripping Installed...

  • Page 106: The Nose Section

    THE NOSE SECTION 1. Preparing The Nose Section Tools Required Masking Tape Drill 1/16 inch Drill Bit 1/8 inch Drill Bit Phillips Screwdriver Jigsaw Rattail File 40 and 80 Grit Sandpaper Part Required Ff #Z734 Two Amber Side Marker Lights Ff #Z721 Four Headlight Stops Bolt Kit #36 Refer to Figures 138 through 140...
  • Page 107 Figure 139 Gas Tank Opening – Nose Section Figure 140 Location of Side Marker Lights...
  • Page 108 2. Assembling the Headlight Boxes Tools Required Drill 5/16 inch Drill Bit 3/16 inch Drill Bit ¼ inch Drill Bit Rattail File Jigsaw Tape Measure Phillips Screwdriver ¼ inch Socket Set Pliers Parts Required Ff #Z721 Headlight Stops Ff #Z720 Headlight Pivots Ff #Z723 Four Headlights Ff #Z724 Eight Headlight Adjusters Ff #Z722 Four Springs...
  • Page 109 Figure 142 Headlight Pivot Holes Figure 143 Preparation of the Headlight Bezels...
  • Page 110 Position the headlight door in the Opening. Position the door in place and check to be certain the headlight boxes fit flush. Tape the door in place once it is in the proper position. Reaching through the 6-inch hole in the nose and the headlight openings, mark the pivot holes on the inner liner. Remove the doors and drill the marks with a 5/16-inch drill bit as shown in figure 144.
  • Page 111 Figure 145A Positioning Headlight Stops Figure 145B Attaching Headlight Stop...
  • Page 112 Install the pivots at the location shown in Figure 146. Drill the holes through the pivot and light box with a ¼ inch drill bit and install the pivots using bolt kit #38. Figure 146A Headlight Pivot Bracket Figure 146B Detail: Headlight Pivot Bracket...
  • Page 113 Install the headlight adjusters and springs on the headlight boxes. Use the adjusters as templates to locate holes to mount the adjusters. Drill 3/16-inch holes and bolt the adjusters down using bolt kit #39 as shown in Figure 147. Make certain the low beams are to the outside of the car.
  • Page 114 Figure 148 Notch Headlight Bezel Place the headlight bezels of the light boxes and drill a 1/16 inch hole through the box using the holes in the bezel as guides. Assemble the bezel to the box as shown in Figure 149 using the screws in bolt kit #40. Figure 149 Attaching Headlight Bezel to Box...

  • Page 115: Installing The Headlight Units

    INSTALLING THE HEADLIGHT UNITS Tools Required Drill ¼ inch Drill Bit 5/16 inch Drill Bit Jigsaw Tape Measure Socket set ½ inch wrench Parts Required Ff #Z719 Long Shaft Lift Ff #Z718 Two Collars Ff #Z717 Two Bearings Ff #Z716 Activator Lift Arm Ff #Z715 Outer Lift Arm Ff #Z714 Two Pivot Arms Ff #Z713 Activating Pivot Arm...
  • Page 116 Measure the inner panel as shown in Figure 151 and notch the panel as shown. Figure 151 Notch the Inner Panel Assemble the lift mechanism out of the car. The long shaft has a lift arm welded in place. Slide a collar on the shaft, then a bearing.
  • Page 117 Figure 153 Installation of Lift Arm Assembly Refer to Figure 154 and bolt pivot arms to pivots on the headlight boxes using bolt kit #43. Make sure the arms work freely before tightening the jam nuts. Figure 154A Pivot Arm Installation Figure 154B Detail: Pivot Arm Bracket...
  • Page 118 Assemble the motor assembly as shown in Figure 155 using bolt kit #44.Check to see that the cam arm and the activator pivot arm work freely, then tighten the jam nuts. Figure 155A Motor Assembly – Headlight Lifts See Figure 155B for measurements. Position motor and bracket. Drill holes and bolt in place with bolt kit #44. In the wiring harness diagrams it will show the wiring diagram The micro-switch is positioned on back of the bracket as shown in Figure 155B.
  • Page 119 Figure 155B Position for Motor Assembly...
  • Page 120 Figure 155C Arm Position – Headlights Open Figure 155D Arm Position – Headlights Closed...
  • Page 121 Bolt the motor bracket to the inner panel using the holes in the bracket as a guide to drill ¼ inch holes in the panel. Allow for free movement between the lift arm and the activator pivot arm before tightening jam nuts. Use bolt kit #44 for this operation.

  • Page 122: Installing The Front Bumper

    INSTALLING THE FRONT BUMPER Tools Required Drill] ¼ inch Drill Bit Socket Set 7/16 inch Wrench 40 grit Sandpaper Jigsaw Caulking Gun Parts Required Ff #Z735 Running Lights Ff #Z770 Grill Ff #Z773 Front Running Sockets Ff #MX193 Silicone Bolt Kit #37 and #45 Refer to Figures 158 through 163 Sand all the edges of the bumper smooth with the 40 grit sandpaper.
  • Page 123 Figure 160 parking Light Installation Run a bead of silicone around the edge of the bumper but out and press the grill in place. Run a second bead around the grill to seal it in place as shown in Figure 161. Allow the silicone to set before proceeding. Draw a line around the nose section about 1-1/4 inch from the flange.
  • Page 124 Figure 162 Bumper Mounting Bolt Holes Figure 163 Mounting Front Bumper to Nose...

  • Page 125: Fastening The Nose To The Main Body

    FASTENING THE NOSE TO THE MAIN BODY Tools Required Drill 5/16 inch Drill Bit 3/8 inch Drill Bit Tape Measure Socket Set ½ inch Wrench Jack Stands ‘C’ Clamp Parts Required Bolt Kit #46 Refer to Figures 164 through 166 Place the nose section against the main body.
  • Page 126 Figure 165 Nose to Main Body Figure 166 Attaching Nose to Main Body – Side Flanges...

  • Page 127: Installing The Nose Supports

    INSTALLING THE NOSE SUPPORTS Tools Required Drill 5/16 inch Drill Bit Socket Set ½ inch Wrench Parts Required Ff # Front Supports Bolt Kit #47 Refer to Figures 168 and 169 Position the support on top of the lower torsion bar tube. Bolt loosely in place with the ‘U’ bolts in bolt kit #47. Slide the support bar against the inner panel in the nose section as shown in Figure 168.
  • Page 128 Figure 169A Front Support to Torsion Bar Tube Figure 169B Front Support to Inner Panel...

  • Page 129: Wiring The Front Of The Car

    WIRING THE FRONT OF THE CAR Tools Required Drill ¼ inch Drill Bit 3/16 inch Drill Bit Pop Rivet Gun Two 7/16 inch Wrenches Parts Required Ff # Headlight sockets Ff # Horn Ff # Horn Relay Bolt Kit #48 Wire Harness Clamps Refer to Figures 170 and 171 Install horn and horn relay on inner panel as shown in Figure 170.

  • Page 130: Installing The Brake Fluid Reservoir

    INSTALLING THE BRAKE FLUID RESERVOIR Tools Required Drill ¼ inch Drill Bit 3/8 inch Drill Bit Two 5/16 inch Wrenches Parts Required Bolt Kit #49 Plumbers Tape VW Brake Fluid Reservoir Brake Hoses Refer to Figure 172 Locate the brake fluid reservoir as shown in Figure 172. The reservoir is attached to the gas tank compartment with plumbers tape.

  • Page 131: Installing The Hood

    INSTALLING THE HOOD Tools Required Drill 5/16 inch Drill Bit Pliers 40 Grit Sandpaper Parts Required Bolt Kit #50 Hood Hinge Hood Rod Refer to Figures 174 through 177 Sand all flanges of the hood smooth using the 40-grit sandpaper Mark the point shown by the measurements in Figure 174 on each side of the hood opening.
  • Page 132 Figure 175 Hood and Hood Rod Installation Place the hood in the hood opening. You will need two assistants to hold the hood in place. The front of the hood should be positioned about ¼ inch from the edge of the deck to allow clearance when opening and closing the hood. The hood is set in place with the front edge below the top desk as shown in Figure 175.
  • Page 133 Figure 176 Positioning: Hood Support Rod Figure 177 Support Rod Fastened to Hood...
  • Page 134 Figure 178 Locating Locking Hood Hold down Bracket Figure 180 Locking Hold down pins...

  • Page 135: Gas Tank Installation

    GAS TANK INSTALLATION Tools Required Drill 5/16 inch Drill Bit Two 5/16 inch Wrenches Parts Required Bolt Kit #52 VW Gas Tank VW Gas Tank Clips Refer to Figure 181 Place the gas tanks in the opening cut for it in the nose section. Place the tank holding the clips over the flange in the gas tank and mark the bolt holes.
  • Page 136 Masking Paper Thinner The Aztec 7 can be painted by any professional body shop or by yourself, if you have had any experience. Any lacquer or enamel car paint will be suitable. Sand the entire body, especially the fiberglass seams, edges and corners, using 120 grit sandpaper. Fill all deep scratches with body filler and sand.

  • Page 137: Mirrors And Trim

    Position the Aztec 7 medallions on each side of the main body in the lower front corners behind the wheels. Using a strong contact cement (e.g. Super Glue) to secure the medallion to the body.
  • Page 138 AZTEC 7 BOLTS Bolt kit packages #12, #13 and #14 were used by the factory personnel to install the doors. Bolt Kit package #43 is not included in the bolt kit but is listed here for reference. #PKG PARTS LOCATON/PLACEMENT OF PARTS 3/8“...
  • Page 139 ¼” – 20 X 1-1/4” PHRHMS Door Glass Latches 10 – 32 X 1” FHMS 10 – 32 Nut #10 Washer ¼” – 20 X 1-1/4” HHCS Dimmer Swithch ¼” – 20 Nut ¼” – Washer #6 X ¾” FHSMS Chrome Trim for Door Opening #8 –...
  • Page 140 5/16” – 18 X 2-1/2” HHCS Headlight Box Hinge 5/16” – 18 Nut 5/16” – Washers 5/16” – Nut Headlight Lift Mechanism Bearing 5/16” – 18 X 1-1/2” HHCS 5/16” – Washers 5/16” – 18 X 1-1/2” HHCS Headlight Pivot Arms 5/16”...

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