‘TABLE OF CONTENTS | SECTION | InrRoDUcrION-aRTS, TOOLS AND SPECIFICATIONS t Parte To Be Purch 7 “Tools To Be Rented. " “Toot Ard Parts IMiscalloreoa in CConsidratone han Buying Pinto j Whesls And Tires Hare And Faster | SECTION bisassexieLy © Pinto oisuembly { Nias Tank Remon | Femoral Of Rear Axl “Femonl Ot Engine Feroel Of String Gear. Hemoval OF Front Superson Steing Column Remaral Pl Asm Site Lever Housing| ' Parking Bako Asem | eh the comsonens SECTION I crass AssemaLy “chassis Asmbly (Roar End). F “Css aesembly [Front Ena Optional Gas Tank. Gos Tank Stance Freval é “Engine Mosifintons Defroster Duct Inealation (Option ~rsaling Vinshista Wipe Motor 3 Winshisid Wrsnor (Options Mounting Te Hood, $ Painting dito Sl Mounting, Hood Orsament| ‘ SECTION BopY AND CASSIS ASSEWALY Swing B04 To Chass j Sion rer er uno Sait a Nasty tach Bee Sent ie it ck Sundar Tan Soserautove ‘st it An ete Led oy Or Fsbenton (pond Son Loch Sa Doer ost Nes ~ Dosa, ap iL21 ize M22 sh wan va wat warFunning Board Brackets (Optional ‘uoning Board (Optional. © Front Bumper Standand} Flat Ber (Optona \fiesr Bumps And Cover \ Spare Tire Mount Ba eer tits. oa : Fog Lights (Optional. Instrument Harness Connections er } ‘Sterng Colin Pin Connoutor To Main Hrs String urn Connect . » ition Sto Blase Renter | retro | papenan8 | Alerts wie Haru ook isso | IsustoneFor'74 And eae Fort || section vit urwousreny rms ano ror Gah. 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PARTS TO BE PURCHASED IMPORTANT: Order these items early due to possible delays with your loca d indshield wiper motor 15 3/4 or 16” between spindles Brake Lines 3/16" x 15! stool - avilable in 12,20, 30, 40,60" lengths Gas Feed Line 5/16" x 10° stet- available in 12,20, 30, 40,60" lengths Gas Return Line 1/4” x 10" stel- available in 12,20, 30, 40,60" lengths Gas Vapor Line 14" x 10" steal - available in 12,20, 30, 40,60" lenaths 2° of 5/16" gas line TOOLS TO BE RENTED 2'of 1/4" as line Double fair female flair couplings for above Tings (as required) 2/8 1.0. 12" neoprene gas hose Hydraulic engine hoist 4/4" soe shaft approximately 30" long 3/4" seltaligning pillow block bearing (Fat ir RAK 3/4, SYH-12¢ or equivalent) 2 poe. 5/16 x 1 1/2" rol pins (spring tension Floor ack pins) fr steering shaft extension MTOOLS AND PARTS. ‘Awortnd "0" Chimps Hod nl =D ——— ==» ar pil Uutty Kai Serene -Pli & Philips Setof Dis 1/8 01/2 Sir Sow Fine Toot Slade Fit Flo & Round Fie oo SS —[p\="-e KA o> O99 7 gl of Rust Retardant Pane ‘Vee Gre Pate Kite Hol Sw Set MISCELLANEOUS ITEMS 90 of wide ergs wpe ‘yp China Markor (Grete Pei Spray ensof blo paint Sandpapsr 60,80, 220, 400, 600 gt Large tbe of contact ent Saco Torae Wrench Hamner Hock So & Fine Toth Blades, cote hie Tape Mew feL. mei and Standard Socket Se, pur 1/10" 6 point deep socket Metre Wrench Sat Standard Wren St tary re rsh fora i catking Gun Tube of Cutking- Acrylic ate Tean aN "77" ray saree Gallon of Pye tsralas ein and hardener (thy Ethy Ketone) (Can of Penetrating noo pts 6a of abbr matting 20 of Man 3)" oar 2 cane 30 "90" pay acheive 2. of 1" inside di, neoprene asin 2it-of S/N" nade cde, copra at line 2s noses 80" wide, 20° hinREPLICA BODY SUPERIMPOSED OVER PINTO CONSIDERATIONS WHEN BUYING A PINTO ‘TYPES ‘The assembly can be built using any 1974.80 4 oylinder Ford Pinto or Bobest, or any 1974. 78. Mustang Il. However, i is adviablo to build the car on as late 8 model es posible, If you use a Mustang It as your component car, You will ned the following items from 3 1974 of later 2300 Cc, Pinto: 41) Strut bars. 2) Motor mounts frame part. 3) Transmission eross member. 4) 4 cylinder non-power storing non ‘AIC "radiator or custom made unit. The kit was designed to use a 4 cylinder with automatic transmission, A standard transmis Sion can be installed but will require mocitice tions. Small block VB and VB's can be used, however, modifiestions will be. necessary. Contact’ our customer service department. ‘We recommend that you purchase a Pinto without sir conditioning and install an ade ‘on unit suchas the one available from our fc: tory, if desired, The radiator, condenser, and evaporator, from an alr conditioned car will all ave to be replace. ‘Due to the space limitations in the kt, power brake and string should not be used; nor are they needed with the decreased weight of the Replica Assembly. WHERE TO FIND A PINTO Loca Newspaper Classified Advertisements Automobile Salvage Yards - Dealerships Neighborhood Fiers/Newspapers Used Car Dealership - Repair garages Bulletin Boards in Gat Stations, Supormar kets, Apartment complexes, Schools, Colleges and Places of Work Tell your friends and fellow workers sbout Your project - they may help Is BUY A COMPLETE CHASSIS We strongly recommend that you buy 8 com plete Pinto and strip it yourself rather than try to buy tho parts separately. While your inital outlay may be more, your overall cost will be lower and you’ will have the convenience of having all the paris you ‘need readily available, BEFORE BUYING A PINTO Before you begin, purchase a Pinto Service Manual. This will help you identify the parts Which you will went to check, Remember that cars with damaged bodies and interiors can be used to assemble your Replica, As 3 matter of fact, a damaged car is Ideal ifthe ‘main components are not damaged,Figure 1 You may want to renew all the mechanical amponents or have someone do it for you. ‘The cost ie very small in comparison to the value added to the finished car. 1D inspect the front end for damage, “There should be no bent or kinked parts. Damaged shocks are no concern as ‘they will be replace. check steering and. brakes. Look for fexcortve play inthe steering, Check for leaky wheel cylinders or master cylinder. These are easily replaced after removal from the body. Oo oO oO Check the transmission, It should shift smoothly and quietly Check the engine. High mileage cars should not be disregarded asthe Pinto ‘engine has proven isa a5 a workhorse capable of years of reliable service Usa your Pinto manual to chack the en sine for possible trouble spots. (Check oil pressure, compresion, et.) ‘Obtain bill of sale and tite for vehicle, also certfiate of non use where applicable. ‘A Pinto that has been rolled over would be deals long as no engine or drive tain components have been damage. WHEELS AND TIRES Due to the configuration of the body and fame, the stock 13” wheels and tires from ‘the Pinto do not give adequate road cleerance ‘and give the car a disproportionate look ‘The car was designed to operate with 14” wheels and E78-14 tres. Because of the fit of the fonders and body, 14” whools with a 3 1/2" insot are required Inset is measured as per diagram, ‘These wheels are available from our factory as an option should you have ciffieulty find ing ther locally. Before you begin, we suggest that you read the manual carefully to get an overall pic. ture of the construction stops. You will have to organize your part, tools, essembly mat rials, and work space for the task. This manual gives a step-by step procedure similar to that used to assomble new cars at our factory. WORKING SPACE You need # working soace spproximstely the Sizo of a two-car gatage, The assembled chae ‘Ss measures 156 inches by 68 inches wide, ‘The fiberslass body occupies approximately the same space. During initial construction‘you will need room for both the chasis and the body until both are finished, One the fiberglass body is mated to the chasis, only half the original space is require. Build two saw horses approximately 82" wide ‘by 20" high. These will be usod to support the body during presssembly before it is permanently mated to the ear Bo sure to allow sufficint space for walking, storage of pats, and access to the car. UNPACKING Your Replicar assembly is shipped in one or more crate and number of eardboard cartons. The total number of items in the shipment is iniested on the shipping documents. Since ‘you may have ordered options, the number of Items in your shipment may differ from other customers. Be sure to sign the bill of lading noting any observable damage. Carefully check each container for evidence ‘of damage. to container or contents. If you find damage, immediately call the shipper’s local office and follow shippers instructions for submitting a claim, Become familiar with the parts, Save your packing lists, As. parts are identified tap ‘them or if fiberlass mark back sides with 8 ‘este pencil, This will enable you to locate correct parts quickly HARDWARE AND FASTENERS When disassembling your Pinto be sure to save all hardware, Most of this hardware will be reused when assembling the kit. Take special care to keep nuts, bolts, and washers in the proper order WARNING NOTE: Check factory service manual for torque specifications when reassembling re moved hardware, There aro some bolts that the manufacturer suggests should not be used after removal bolts and nuts should only be replaced with equivalent parts, Replacement parts must be of equal or better strength as indicated by standard bolt and nut markings (eadial tines on bolt head, raed dots on ruts) ‘Special chrome hardware is supplied with the deluxe kit. However, ordinary fasteners are not supplied since they ean be obtained from hardware or automotive supply houses. For ‘your convenience an optional nut and bolt peckage is available. (See sopondix for nomenclature.) wiring “The assembly uses the wires and plugs intact located on the Pinto stering column as well as somo of the plastic connectors from the car Several choices aro avalable. Fist you can purchase our optional wiring harness, This is 4 eal time saver, especially if you use our ‘optional gauges and accessories. (Other methods include fabricating your own harness. Follow: the schematic in the wiring ‘ction. Modifying an aftermarket harness, ete. WELDING Al structural parts can be bolted in place However, a minimal amount of welding is recommended. ‘The parts you choose to wold ‘te dependent only on your praferonces. Welding usually gives greater strength and it prevents the possibility of bolts working loose. Perts that may be welded include the rear bumper bracket, drive shaft, stooring shaft, running boards, anc exhaust ‘Thoso parts can be welded with a small are Welder or taken to a machine shop for wold ing. The work can usually be done in lest than an hour. Most cities have mobile welders who will come to your garage or shop and do the welding, Unless you ara an experienced ‘older, we recommend that you contract out ‘these items. For convenince, you can bolt the parts in place initially, then later weld them perman- ently al atthe same time. BEFORE STARTING Be sure to read this manual all the way through before starting work D1 Have all the tools you need before you1D Be sure your work space fs lege enough, seve all parts and hardware, that you remove. If you try to buy all the pieces Separately they will cost lot more, Have masking tape ready to label parts, attaching hardware, wires, fuel lines, clips, ete, It would also be 2 good idea to ave a variety of small containers to hhold small loose items such as nuts, bolts, and washers Make sketches or take Polaroid photos (of the assomblies that seem complicated. This can help you lator when you are assembling the kit, GD Keep records and receipts, You will need these when you register your com: plated car. Call your state department of Motor Vehicles and find out what their requirments are, Get a bill of sale and title when you purchese your compon- font car. We supply 2 manufacturers state of origin MSO} with each assembly kit. USE COMMON SENSE Develop safe work habits, Take every possible precaution. Follow theie basic Do's and Don'ts, bo Do use safety stands to support vehicles. sacks ar for iting only oO Do Keep 8 fire extinguisher in your work Do keep a first sid kit ia your work Do disconnect the battery (negative) cable whenever working on elecriel system. Do disconnect and remove the battery from the component car before starting alisassombly. Do use the proper tools. Do clean and maintain your tools. Clean Your work aree often, Do use approved containers for gasoline and flammable liquids. Put away and out ff reach of children when not in use Do wear eafety glasses or gogsles when ‘nding, driling, sanding, painting, lasting ‘or when handling the battery Do read al instructions Do pay attention to warning labels. Do use adequate ventilation when using ‘chemicals, spraying paint, ferglassing. Wear a mask over mouth end nose when necessary Do use electrical extension cords of the proper gauge and with proper plugs in good condition. Is Do wear proper clothing and shoes remove ties, jewelry, and other items that can get caught in moving compo- Don'ts Oo a Don't smoke when working around gaso- line or other flammable choricals Don't use open flame heaters around geoline or when using flammable chemicals Don't smoke when working around the battery. Don’t run engine in a gprage without proper ventilation. Don't attempt to servo air condition ing units without proper tools oF tain ina, Don't use air concitioning refrigerant (F-12) in the presence of an open fame, Don't leave tools where someone can trip over them.SECTION DISASSEMBLY Lo PINTO DISASSEMBLY Gi For disassembly you will need 2 jack stands, wooden locks to support en: ine, 8 floor jack or hydraulic jack and an engine hoist. e sure to save and mark all hardware for use on the new frame. Jack up rear end and secure on jack Stands under frame, Disconnect battery Cables before proceeding any further Feter to factory shop manual © WARNING: Make sure battery is dis connected and positive (+) coll wire is disconnected. Avoid smoking in the Work area, It is @ good idea to have a 60> fire extinguisher handy, Drain fuel Into an approved container. a evLINDER Be 5 a BARES Figure 1na GAS TANK REMOVAL ir you are going to use the optional fuel tank, that offers more trunk space, It is not necessary to remove the fuel tank. Otherwise remove the stock tank az outlined below, Tine below Unplug sending unit connector from the bottom of the fuel tank. Cut connector off leaving a 12” lead and save. Drain 42s into an approved container from the large fiting on the sender plato. fe ave inlet hose from vapor valve on the top left of the tank, Unbolt rear of teach sap lower tank. Grain any remaining fuel from the tank Remove fille neck and tape oF cover ‘openings, allowing @ small hole. for fumes 10 escape. Mark straps and filler neck hardware end save for use later. REMOVAL OF REAR AXLE 1D Place a floor jack under the rear exle ‘of the Ford and jack up the rear end high enough to get two jckstands under the frame just forward of the rear whee! housing an each side of the frame. Gi disconnect the drive shatt by removing ‘the twa U:bolts connecting the shaft to the differential, Tape the bearing in place, and carefully lower the drive shat.Qo Qo Pull on the drive shaft until the front splined end is free of the transmission, Plug the drive shaft opening in the end fof the transmission to provent lost of fluid when removing the engine. A plas- tie oF styrofoam cup ean be taped in place to plug the opening From inside of the car lift up on plas tic emergency brake housing. Remave Jam nut and adjustment nut from park Ing brake adjustment shaft. Pull out from under the eat. Save the yoke and adjustment shaft and nuts for use Inter. Using 2 cold chisel, remove the «wo brackets holding the upper end of the flexible brake tine. Also remove the emergency brake cable from the chassis by prying off the retainers securing the housings. NOTE: Leave the bracket attached to the brake line. If availabe, an air chisel will sp2ed up this step. O WaARNING: Place jack under the rest axle to take up the sack when comoving the shock absorbers. If you don't, the ‘axle may spring loose when the nuts fare removed Unbolt the two shock absorbers from the frame, leaving the brackets attached 1 the frame, Remove the rear spring brackets from ‘the frame and let the rear springs hang down. Leave the brackets attached 10 the springs. Remove the long bolts holding the front fond of the rear springs and detach the springs. Save the rubber bushings, bolts, and nuts The rear axle assombly is now free to remove. Rol it out as complete asem biy and set aside until ready to mount fon the new frame. Figs na7 exausT MANIFOLD ——" Figured ha EXHAUST SYSTEM NOTE: Depending upan the year of your tar and the location originally manufactured for the exhaust system may vary slightly. However, these removal guidelines can be followed in most cases, Consult your fe: {ory service manual for servicing information ‘on your partieular ca. 1D disconnect the exhaust pipe at the flange on the exhaust. manifold. Re move any clamps supporting the front pie. Remove brackets supporting the pipe in front of the catalytic converter st the eat in front. of the muffler and. the bracket atthe rear of the muffle. Lower assembly and save with all mount: ng bracketsREMOVAL OF ENGINE NOTE: Save all hardware for rouse later Gi untoit the hood at the hinges and re move the hood completely from the Git the battery has not already been removed, disconnect the cables and remove the battery from the car. If you fare going to reuse the same battery, It should be charged once a month, Remove air cleaner and exhaust mani fold shroud. Remove connecting hoses “Tape the top of the carburetor closed 10 prevent dirt from getting into the ‘engine. Drain float bom! O Disconnect throttle cable, wiring to engine, heater hoses, ete, The specific connections will diffe slightly depend: ing on the model year of your Ford, Tay nose connections and electrical wiring with pieces of masking tape. If you don't know their function, simply mark both ende with the same letter or number code and during resssombly, simply match them up. G_cAUTION: If your car has an air cond tioning unit, remove the compretsor from its mounting bracket, with the refrigerant lines attached. Position out Of the way. If you decide to remove the Unit, it must be evacuated, Consult 8 Pinto service menual for instructions ns FieR12 refigerant should be handles withthe proper precautions. 1D Remove sccesories such as voltage requ: lator, electronic ignition, ignition coil, catbon canister, ete. Save all connect ing hoses and wires and save the attach Ing hardware. G drain coolant from radiator. Remove hates, unbalt and remove radiator and fan. Save raditor and all hardware for reuse later, 1 NoTe: If your car has an sutomatic twansmission be sure to plug the trans: mission fluid cooling lines to prevent contamination of transmission fluid. Figures us © disconnest all shifting ingages, back: ‘up light connoctor, neutral safety sith connector, etc. from the trans: tt your ear has @ standard transmission the shift lever must be removed from inside the car before the engine is Femoved, Loosen the lock nut holding the shift knob and take both off the shift lever. Place the shift lever in neutral fand remove the backup light switch, Cut the connector for the switch with 24” lead and remove. Remove the boot fand compress the corrigated rubber Spring and remove the snap ring. Slide the spring up the lever; bend the tabs fon the shift lever lock, Carefully un ‘thread plastic nut and pull lever from housing, Save all pars. NOTE: Be sure transmission is plugged to provent leakage of fluid when hoist ing 1D Unbott the transmission support cross member and completely remove the U shaped bracket 1D inspect the engine end transmission to be sure itis free to be lifted out and ho wires oF hoses ere still connected O Hoist the engine up and out of the en- sine compartment.Figure 7 ion as you lift the engine and for installation inthe now chasis G Remove the motor mount brackets 12 0 Set the engine aside until you are resdy from th ca. uaREMOVAL OF STEERING GEAR GB sack up the front end and place wo ‘more jack stands under the frame just ‘behind the front Fenders _Remave the front wheels 1D Remove cotter pins and nuts from the the studs from 5 joint separa Gi emave the one bolt that holds the pinion shaft to the flexible coupling TD Remove bolts holding rack and pinion to. chasis thet go through the front cross member. Save all nuts and bolts, rubber bushings, et. Figure 8 naREMOVAL OF FRONT SUSPENSION a If installed on your car, remove the stablizer bar as follows: remove nuts fon studs attaching end of stabilizer bar to lower control arms: move stabil Teer brackets from frame, Discard the stabilizer bar. It is not required on ‘he assombly, Unbolt the strut bars an each contro! farm and the nuts attaching the struts to the chasis, Save all bushings, washers sand outs UUnbolt the shock absorber nuts at the top of each shock, Unbolt shock from ‘control arm and remove from suspen: sion. If worn, replace. Save all hard LUnbot Front brake lines from breke hose ‘going to each whoo! atthe brackets. Use ‘an open end fiting wrench. Leave the hoses attached to the wheels. Tie outof ‘the way, Chisel off the retaining brackets spot welded 10 the chassis and retain for use on the new ches WARNING: Place a jack under the lower control arm to compress coil sorings when removing. This precaution elimi tes the chance of any personel injury ‘due to the sudden release of the coll spring Using 2 hydraulic or scissors jack, take Up tention on the underside of the loner control arm to compress the coil spring ‘on ane side of the cr. Disconnect the two 3/4 inch nuts hold Ing the upper control arm. Lift the upper control arm up end over the top of the wheel asembly. Release the tension on the jack slowly, Unbott the lower control arm from the ross member and remove the entire ne oO ao suspension assambly from the chassis, “Take the spring out and be sure to save the circular rubber spring pad. that cushions the upper end of the spring. Remove the front suspension on the op posite side of the car using the same procedures deseribed above NOTE: If you decide to mocity the wir: ing from your Pinto and use it in the assembly, the wiring must be removed from your component ear. Disconnect all connectors from switches and plugs fand attach identifying tags. If you de cide to use the harness available from four factory, lip the connectors off ‘a you go along as outlined in the removal instructions. These connectors will be spliced to the new harness and rousedros ifSTEERING COLUMN REMOVAL, O_Unbott the Universal jointat the bottom ff the steering shaft and remove from the car D From the inside of the ear remove the plastic lower shroud and disconnect, Plastic connectors to the steering column plug and the connector that goes into ‘he ignition switen on the top of the column, TD Unbolt the four nuts attaching the steering column collar brackets to brake support and remove along with ‘the rubber boot. Save all hardware C1 it you are not going to use the Ford wiring harness, cut and remove. the plastic connectors thet go to the plugs land ignition switch on the steering column. Leave at least 12” of lead wire. Algo cut the male and female 11 pin connectors from the haress also leaving approximately 12” lesds ‘These connectors ate the same at the connector on the steering shaft, premonee q G If you decide to use the Ford wiring harness it will require extensive modi fications, Remove 9s one unit from the Figure 10 mntMASTER CYLINDER, BRAKE PEDAL AND. CLUTCH PEDAL ASSEMBLY GD disconnect brake tines from master cylinder to brake differential valve and lings from velue to front and rear brakes. Draw 2 diagram of valve showing line locetions as they can vary depending ‘on type of valve used inthe ear. Gi From inside the car remove the cotter pin from the orake pedal shaft. Slide Stop light brake switch off shaft. Cut wires 10 switch connector leaving at Teast a6 inch lead, Save switch and 1D From the engine compartment remove ruts and bolts securing master cylinder ‘through fice wall. to pedal assembly. Remove unit from the ea. Gi side out shatt holding brake pedal Remove plastic bushing and save pisces for use later. if your car is a 74, the clutch pedal will be removed along with the brake pedal, If it is a "75 oF later, unbolt Clutch pedal assembly from ‘side of brake bracket, Remove adjustment cable ‘and brackets. Save for future use Gi Nore: if your car has vacuum assisted bakes, removal is accomplished. in ‘the same manner. However, the vacuum tnit wil not ff the assembly nor is it necessary with the lighter weight, Remove master eylinder from vacuum Figure 17 nazACCELERATOR PEDAL, SHIF Gi From inside of the car unbot and re O ‘move aceslerator pedal assombly "T LEVER HOUSING (AUTOMATIC) Femove set seraw and pull handle from shat. PARKING BRAKE ASSEMBLY Remove the plastic housing from the parking brake and sve © etech and remove throttle cable from Remove screws holding dial housing) Remove wo bolts holding brake evr to engine compartment. ave all parts and _-«COVErto shift ver housing. Remove she Yigr, Cut wire to emergency brake lis. four bolts holding housing to flor. yi g inches from connector. Remove Disconnect ight st plug on bottom Senony Sean Pall housing up and ob. Save al pisces. They wil be used. in the assembly. nevamen Pug Soaetee ec aca Sf = £ Figure 12 eraREMOVAL OF ACCESSORIES Remove the dimmer snitch trom the floor. Alko the connector to tho switch with 12" leads. Remove the windshield mirror by cutting adhesive on beck of mirror ‘mount while simultaneously pulling on the mirror. Or you ean remove sot sere land remove mitrar from metal mount ing bracket, Simply purchase a new mounting tab trom your local auto supply store 1D NOTE: Heat may be applied to the Windshield to. loosen adhesive but this can erack the windshield Remove side miror, if desired Gi if you choose t0 use the orginal brake fand fuel lines they will have to be substantially altered, They should be Femoved now, If you ate going to use rrew lines simply remove retaining elias end save. Disconnect ond save the speedometer cable Remove the directional and hazard flashers with their bracket and com rectors. Leave approximstely 12 inch reads, ‘The plastie storage compartment if not sir conditioner equipped, canbe re moved with its attachment. bracket ‘Any other components that you may Wwish to. use on Your assembly should be removed now, “The hood support rad is ideal for use on the assembly and should be removed use and sived. Also cut off the hood sup port retaining flange and save, CHECKING THE COMPONENTS Now isthe time to check all ormponents you have removed for wear. Pars that are worn for damaged should be replaced with equiva Tent parts from your auto supply dealer ‘oF Ford dealer. In addition, you may want to clean and paint some of the parts that need corrosion protec tion oF for appesrance. Sand blesting and/or steam cleaning is popular NOTE: We strongly urge you spend a litle extra time in renawing sll damaged and worn parts. When completed your assombly will Feflect the extra time and attention spent here