T-1 TRUE PERFORMANCE FRONT END INSTALL INSTRUCTIONS

T-1 INSTALLATION

INSTRUCTIONS

STEP 1) REMOVE OLD BEAM FRONT END COMPLETE (EVERYTHING FROM SPINDLE TO SPINDLE)

STEP 2) REMOVE BOTH LOWER FRONT BULKHEAD GUSSETS (SEE DIAGRAM 1 & 1B)

STEP 3) TRIM BOTH SIDES OF BEAM CRADLES 1/4 INCH (SEE DIAGRAM 2)

STEP 4) TRIM LOWER PORTION OF BEAM CRADLES ON SOME MODELS WHERE LOWER CRADLE STICKS OUT TO FAR TO INSTALL FRONT BULKHEAD WITH PLATE #1 IN PLACE, OR TRIM LEVEL WITH LOCATOR (SEE DIAGRAM 3) ALSO NOTE: WE HAVE LEFT FRONT PLATE ONLY TACKED IN PLACE IN CASE YOU CHOOSE NOT TO TRIM THIS AREA. IN THIS CASE SIMPLY CUT TACKS AND INSTALL FRONT PLATE AFTER BULKHEAD IS ABLE TO SADDLE VW BULKHEAD. BE SURE TO WELD AROUND ALL 1.5 INCH SQUARE TUBES WHERE THEY COME OUT THROUGH FRONT PLATE.

STEP 5) SET CRC BULKHEAD ASSEMBLY ONTO VW PAN BULKHEAD WITH OR WITHOUT FRONT PLATE. (SEE DIAGRAM 4)

STEP 6) INSTALL CRC BULKHEAD #1 AND BOLT USING FOUR OF THE A-ARM PIVOT BOLTS, FOUR STEEL SLEEVES FROM INNER A-ARM BUSHINGS, AND TWO SLIPPER WASHERS PER SLEEVE TO PROPERLY SPACE FRONT PLATE FOR WELDING.

STEP 7) BOLT FRONT BULKHEAD TO VW BULKHEAD USING THE ORIGINAL BEAM HARDWARE AND ONLY LIGHTLY SNUGGING THE BOLTS TO HOLD THE CRC BULKHEAD AGAINST THE VW PAN FRONT CROSS MEMBER (THE AREA THE MASTER CYLINDER BOLTS TO). BE CAREFUL TO NOT OVER TIGHTEN THE BOLT AND BEND THE FRONT PLATE.

STEP 8) WITH CRC BULKHEAD INSTALLED, MEASURE FROM RIGHT UPPER REAR A-ARM HOLE IN CRC BULKHEAD TO RIGHT SIDE MACHINED HOLE IN TORSION HOUSING, AND REPEAT FOR LEFT SIDE (SEE DIAGRAM #5). THESE MEASUREMENTS NEED TO BE LESS THEN 1/16TH OF AN INCH DIFFERENCE. IT MAY BE NECESSARY TO SHIM ONE SIDE OF BULKHEAD TO ACHIEVE CORRECT MEASUREMENTS.

STEP 9) MEASURE FROM RIGHT SIDE OF BULKHEAD TO LEFT REAR MACHINED HOLE IN TORSION HOUSING AND FROM LEFT SIDE OF BULKHEAD TO RIGHT REAR MACHINED HOLE IN TORSION HOUSING. MEASUREMENTS MUST BE THE SAME. IF NOT YOU NEED TO MOVE THE FRONT END UNTIL MEASUREMENTS ARE LESS THEN 1/16TH OF AN INCH DIFFERENCE.

STEP 10) TACK WELD FRONT END IN PLACE AND DOUBLE CHECK THE MEASUREMENTS. IF EVERYTHING IS STILL GOOD START WELDING FRONT END IN PLACE ON HORIZONTAL SURFACES THEN ON VERTICAL SURFACES. (NOTE: BE SURE TO PLACE TACK WELDS IN ARES YOU CAN BE CUT EASILY).

STEP 11) NOW THAT THE FRONT BULKHEAD IS WELDED ON YOU CAN ASSEMBLE FRONT END AND MAKE BASIC ADJUSTMENTS TO ALLOW CAR TO ROLL. WE STRONGLY RECOMMEND HAVING PROFESSIONAL ALIGNMENT PERFORMED.