Box 17
Issue 67: Retrieve parts and wire assemblies from the last box.

Step 1 Get the tank cover and filler pipe. Secure the filler pipe to the tank cover, notice The fit tab on the pipe. Secure with a BP screw.

Step 2 Put the tank cover onto the chassis as shown and secure with 2 GM screws.

Step 3 The rear floor panel covers the circuit board area. Secure with 2GM screws.
I had to gently clamp the chassis behind The rear seat backs to get both of the screws to start.

Steps 4,5&6 Connect the loose wire assemblies as shown. There are Five connectors to make up. Issue 67 is complete.

Issue 68 Drivers side door and rear view mirror

Note: I have been polishing and waxing all the body parts. The powder coat finish shows a slight orange peel. It doesn’t take long and the paint improvement will be worthwhile. I use a regular car polish product and car wax.

Step 1 Secure the door handle with one AP screw.

Step 2 Place and secure the inner door lock with a GM screw. See the build photo. Black on black is tough to photograph
.
Step 3 Carefully press the mirror lens into the mirror housing. It is a plastic pin on the mirror.

Step 4 Mount the mirror assembly to the door with a GM screw. Issue 68 is complete.

Issue 69 Door hinge and window assembly

Step 1 and 2 Place the door hinge into the slot at the front inside of the door. Secure with the hinge cover and a GM screw. Check operation of the hinge.

Step 3 and 4 Put the two pieces of protective black tape onto the inside upper surface of the door to protect the window. Save the gears and window until Step 8 of the next Issue.

Issue 70 Finishing the inside door panel and window assembly

In this Issue we will apply a faux leather fabric material. Take your time with these two pieces of material, it looks really good if applied correctly. It took me several tries at each piece to get it right.

Step 1 Start at the back of the upper piece and apply moving forward. Don’t stretch the material.

Step 2 Press the pins on the door handle base into the holes as shown.

Step 3 Press the two vertical pins of the lever part, 70F, into the door panel 70C.

Step 4 Mount this assembly to the panel and secure with one BP screw.

Step 5 Press the door trim, 70B, into the four holes on the inner door panel as shown.

Step 6 Again, take your time removing the backing from the faux leather. Place the panel as shown on the lower part of the door panel.

Step 7 Mount and secure the arm rest with two BP screws.

Step 8 Place the gears onto the pins on the inside of the drivers side door. The stepped gear goes on the lower pin. Flat gear goes on the middle pin. The gear with the arm on top. Secure with flanged DP screws. Check operation before moving on. Loosen screws if necessary.

Step 9 Place the window on the pin of the arm gear as shown. Check that the window moves smoothly.

Step 10 Get the interior door panel and mount it to the door with six AM screws. Check operation or the window.

Issue 70 is complete.