After getting my rear strut angles finalized, I knew there was no way I'd leave the old hole exposed. It just looked unfinished and ugly.


I had a plan though. Grind the hole flush with the body leaves a bigger hole.


Laser cut two 18 gauge fillers.


Tack in place.


I fully welded the circumference and ground flush. It's difficult to snap a clean shot of a surface that has been ground. This will look good once I get some filler, primer and paint on it.




I had a clutch master from Rodney. This was for the old setup with the larger hole to fit the earlier cars. Since my clutch pedal was bent, I swapped to the newer setup that I had. This created a problem. The new style arm has a smaller pin. We can't have that. A new brass bushing was made, simple. Problem solved.


Here, a new clutch is waiting to be installed.


The flywheel was in great shape and as seen here, torqued to spec with a drop of Loctite on the threads.
1st pass, 39 lb-ft
2nd pass, 25°


Kevlar impregnated clutch disk installed. Here you can see the centering tool in place.


Followed by the pressure plate torqued to 18 lb-ft.


Of course, a new concentric slave cylinder had to go in.


From here, I will verify the clutch depth and measure the throw out bearing range. It's always good to be sure.

I picked up an 88 cradle from a member on here.


This obviously won't work for my needs, so it too will get modified. Sorry guys, turn away if your squeamish about hacking up a perfectly good 88 cradle. I cut the front and rear sections out as all I wanted are the side rails.
PS-This will be used for a future project.




I then spent some time removing all the offending areas and excess brackets/mounts. I will be making something that fits my needs and wants. Before you ask, I did make a fixture/jig that will allow me index the key points. This will also hold the rails in the factory position for when I weld in the new rectangular tubing. I'll post pictures when it's done.

In time, I'd like to modernize the lighting on the car. This is the start. A set of LED side marker lights.


These are sold by member Danyel and can be seen here -> http://www.fiero.nl/forum/Forum4/HTML/066792.html.
These were very nicely made and packaged with clear instructions too!
Very professional and I recommend dealing with the guy.

Thank you Danyel for an awesome product.

[This message has been edited by Lunatic (edited 04-03-2016).]

quote Originally posted by Quad Raider: Amazing amount and quality of work. Thanks for posting all the photos, too.

X2 on that comment... I actually came here to say the same thing.

This is very impressive work. Talk about an ambitious human being!

Very cool build!

[This message has been edited by ITALGT (edited 06-02-2016).]

Before installing the fuel tank, I had to make sure the sending unit and fuel gauge were going to work together. I knew the sending unit was 0-90 Ω but I wasn't too sure about the fuel gauge. The part number was smeared and I couldn't look it up. Do I have another option you ask? Why yes, yes I do.

The solution is quite simple. Use a spare computer power supply and hook the assembly up and see what happens.
Here is the gauge that I'm using. Equus 8000 series.


PC power supply.


Jump the two terminals as shown to "turn on" the power supply.


If you probe the yellow and black pins, you can see 12 volts is present.


With this simple circuit wired up, here is my progress.
Fuel sender in the "empty" position.


Fuel sender in the "half" position.


Fuel sender in the "full" position.


Here's a little video to show the smoothness of my hybrid sending unit in action.


Now that I'm certain it works, I put it back inside the fuel tank.

[This message has been edited by Lunatic (edited 07-13-2016).]