Chapter 1

While this instruction manual is intended to provide guidance in building
your Diablo Kit, you may find new ways to accomplish some of the
steps. That is the fun in building your own car. You can be innovative and
creative to make it even more unique.

Tools Required

Hear is a list of tools you will need

Socket set- standard and metric
Screwdrivers- philips and flat
Wrenches- box end and cresent
Flaring Tool
Floor Jack
Jack Stands
Hammer
Electric drill
Electric grinder
Assorted drill bits
C clamps and spring clamps

Optional Tools

Air Compressor
Welder
Drill Press

Additional

Reference

Material

We would also recommend

that you get a manual dealing

with the care and maintenance

of the Fiero. One

such book is a Haynes manual

as shown below. There

are other manuals as well

that you may want to pick

up. The reason to have

these books is to answer

any questions that may

come up in dealing with the

actual mechanical aspects of the car. For example if you are planning on

removing the engine. These manuals will be invaluable assisting in these

tasks.These books are available at most autoparts stores.

Skills required

Welding
It will be necessary to use a welder in constructing this kit. This will be required for the stretching of the frame as well as when parts have to be fabricated for the car. If you are not familiar with welding, you may wish to hire a professional to do the structural part of the kit or possibly take a course through your community college.

Body Work

When fastening metal components like the hinges to the deck lids, the

methods that are used are as follows:

1. Grind the surface to which the component will be fastened to remove the waxy coating.

2.Test fit component to make sure there is a good fit.

3. Mix and apply a coating of bondo to the component similar to applying butter to a piece of bread

4.Apply the component to the surface and if necessary, clamp lightly in

place.

5. Let bondo dry thoroughly according to manufactures instructions.
6. Cut a piece of fiberglass matting or cloth to allow an overlap of at least 2”

around the component.

7.Mix up enough resin and hardener to saturate the matting or cloth. take necessary precautions to cover the threads of any bolts to make sure they are not filled with resin.

Electrical Work

You will need to be able to make electrical connections and splice wires into the existing Fiero wiring harness. Because the body is made of fiberglass

and does not conduct electricity, it will be necessary to run ground wires to

all connections that are made in the fiberglass.

You will need to have access to an Ohm/Volt meter for checking connections.
If you are using the Fiero as a donor, you will need to have access to the

Fiero wiring diagrams. A helpful hint is to get some map markers and actually

color in the wires for easier readability.

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