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Build Diaries => Countach => Topic started by: Correy7 on October 24, 2017, 12:18:38 AM

Title: 1986 Countach Replica
Post by: Correy7 on October 24, 2017, 12:18:38 AM
Hello Lamboclone forum -

Guys I am brand new to this site and am looking for assistance, advice and insight regarding a new acquisition of mine.

After 15+ years of looking; I have purchased a nearly complete 86 countach replica, built on an 88 Fiero non-stretched chassis.

I am learning quickly that this will be a rewarding but enduring project and first task to tackle of pronvincial safety is that of the door strut.

As it stands now, and quasi visible in the video link below the passenger side door strut has lost almost all compression and will need to be replaced...the question I don't know the answer too is how to access the mounting points. One in side skirt is visible, one in door is not.

I have no record of original kit manufacturer and am unsure how to dissemble door to access strut head, I am of the assumption that interior door panel would be removeable for access but can only assume this based on other incomplete skits I have seen, how to know wether this is screwed together or glued is another challenge.

I am mechanically inclined, patient and seeking a few starting points to begin tackling this.

Apologies if this had been entered in the wrong area but will learn the ropes quickly as I imagine I will be here frequently! 

https://doc-08-68-docs.googleusercontent.com/docs/securesc/4rseirjb2brpk43iridrbka3cv1jbef0/dp6pm2iect6kecmq8ni928f5e4d94p27/1508817600000/15069435388295558182/15822383574801962991/0B2HvWbhZoWx5bTJRVFBKRG9Mc28?e=download&nonce=i090a63uj9bfs&user=15822383574801962991&hash=p3s980d4semfm4fqg3to9dj5v4to6kmr

Please let me know your thoughts should there be any you think may help.

Cheers,
Shane
Title: Re: 1986 Countach Replica
Post by: Correy7 on October 24, 2017, 01:32:49 PM
Apologies guys -

I was able to upload the video to youtube moments ago...below link should work:

https://youtu.be/b_auDdUkA-A

The vehicle was shipped to me from New Brunswick to Vancouver, BC in August however during shipping the passenger side window was broken, glass has been cut, tempered and installed as of yesterday - took a while to find a local professional capable and willing to do so.

I should have the car in my garage as of late week at which point I can take additional footage - this original video was done by seller.

My trending thought is that they way in which door struts are accessed is through removal of interior door card? This coming to me after examining build manuals and videos...would I be on the right track?
Title: Re: 1986 Countach Replica
Post by: 01Lambiero on October 25, 2017, 11:22:14 AM
Shane: Please post at least 6 pictures of the door from various angles to help us out.  Just click the "attachments and other options" at the bottom of the text frame on the "Reply" window to load your pictures.

01
Title: Re: 1986 Countach Replica
Post by: 88.5countach on October 25, 2017, 01:12:09 PM
Shane: Please post at least 6 pictures of the door from various angles to help us out.  Just click the "attachments and other options" at the bottom of the text frame on the "Reply" window to load your pictures.

01
More pics would be good but your on track with removing the inner door cart to get access.  Once off it should be accessible.
Title: Re: 1986 Countach Replica
Post by: Correy7 on October 25, 2017, 07:28:39 PM
Fellas, appreciate your responses and willingness to help.

I will upload pictures as requested when car is in my possession and try to take as many as possible to help with the assessment. I spoke with the glass installer today and asked him to do a little recon on the door, he mentioned that it appears to be  a door card with fastener clips however was weary of doing the repair work himself due to brittleness of fiberglass that he experienced when inserting window frames.

Will follow up on this next week - parking brake cable is being replaced over course of next day or so, that should be last detail before I can get her back here.

Any idea from video who would have manufactured this kit?

Thanks all!

Title: Re: 1986 Countach Replica
Post by: Correy7 on November 02, 2017, 11:46:55 PM
Hello All,

Please see below a link to video of the door in which I need to replace the lift strut (actually I need to replace both) - kindly let me know any thoughts you may have as to how to access strut both in skirt and door itself.

Youtube Link: https://youtu.be/0zCJYc4Qqxo

A few other items that I need help with:

1. Any recommendations or threads on headliner replacement "how to" and;
2. I cannot seem to locate the washer fluid reservoir, is this not typically located in front compartment of fiero... I would assume the same on this kit but am having difficulty finding anything.

Last few items for BC safety are:

1. Door struts
2. Headliner
3. Washer fluid (functional) and:
4. Seat bolts need to be tightened

I know you guys help newbies like myself because of your enthusiasm for this hobby, I hope to do the same someday as my knowledge grows and really appreciate any insight you can offer along the way.

Boy am I excited that she's now sitting at our place, a few more items to go and back on the road :)
Title: Re: 1986 Countach Replica
Post by: 01Lambiero on November 03, 2017, 12:24:57 PM
We need to see close up hi-res still pictures of the attachment of the strut rod to the lower mount along with pics of the door card edges.  Most times the strut snaps onto a ball stud on lower mount.  Does the speaker in the door card move in when lightly pushed on?  This will tell us whether it is screwed to the door inner or the door card.  The speaker may have to be removed first in order to remove the door card.  As for the washer jar,  the washer fluid pump is usually located near the reservoir jar.  Have someone activate the washer pump and follow the sound.  You may also follow the washer squirter hose to the reservoir. 

01
Title: Re: 1986 Countach Replica
Post by: Correy7 on November 03, 2017, 09:56:03 PM
01 - great thank you.

I will take photos as you mentioned and get them up here sometime this weekend.

I can confirm the speaker appears to be attached to the door card and appears as though it can be removed quite easily, it is right around the point where I can now feel via door cavity that the struct connects to the door frame.

I will attempt to remove the speaker tomorrow to see if strut and connection to frame are visible and snap a few photos all round. 

Great advice on the washer pump, I will give that a go tomorrow as well and do my best to gain  aline of sight on its whereabouts.

Thank you  :)
Title: Re: 1986 Countach Replica
Post by: Correy7 on November 04, 2017, 09:32:10 PM
Fellas..

Success! I was able to get the door card removed today and 01 you were correct, removing the speaker was key. I have been able to detach one end of strut from door frame and have located torque headed bolt head just above the wheel well in which connects the other end to frame, there was an access point in interior wheel well although a tight space, will need to get the ratchet and extension out tomorrow to reattempt loosening of this end.

However it appears as though the strut end that remains attached (stroke end) is threaded into the end piece that is bolted to frame, would it be wiser to simply unscrew strut from end connection than to disassemble connection to frame? I have taken pictures (attached)...possibly these will help to illustrate what I am attempting to explain.

Last but not least...any idea where I can locate a strut with part number as identified by the photo?

Cheers,
SC

Title: Re: 1986 Countach Replica
Post by: 01Lambiero on November 05, 2017, 12:20:39 AM
1984-1990 Dodge Caravan rear hatch lift (according to the number on the gas strut #4775).  You should be able to pick up this part at most auto parts stores.  I don't know if the end is removable or not.  You may have to take the lower end apart from the vehicle.

01
Title: Re: 1986 Countach Replica
Post by: Correy7 on November 08, 2017, 01:32:15 AM
01 - success! With a little elbow grease, multiple curse words and a few lucky bounces I was able to remove door cards, remove struts and replace with new 4775's that were easy to order at Lordco (same day). The doors function 100% better than before, I am really impressed! Thank you again for the guidance fellas, saved me many $$ along the way!

Not to mention, the car was missing the key for door locks when it arrived here in Vancouver, the seller did not have a copy, lo and behold the original key must have been forgotten in the door during the build as I found it in a pile of dust in door interior  when replacing the strut ..I was pretty happy about that, one last thing that would have needed to been replaced! I.e lock cylinders

Next up: headliner repair, front latch repair and last but not least , washer fluid pump attention.

See picture for outcome of strut replacements!
Title: Re: 1986 Countach Replica
Post by: 01Lambiero on November 08, 2017, 02:26:49 PM
Owww!  My neck!!!!!  Now, how to fix your headliner (if it has just come unglued from the hard board form).  If the foam on the headliner has deteriorated, it should be removed with a wire brush (very messy) before spraying the adhesive on.  Here are a few youtube videos which may be helpful.  Some have removed the entire headliner board form and others have reglued it without removal.  Have fun. ::bounce ::thumbup

https://www.youtube.com/watch?v=jXdS0nBVMZc (https://www.youtube.com/watch?v=jXdS0nBVMZc)
https://www.youtube.com/watch?v=DryrSaNm7W4 (https://www.youtube.com/watch?v=DryrSaNm7W4)
https://www.youtube.com/watch?v=f91Ht0J45jc (https://www.youtube.com/watch?v=f91Ht0J45jc)
https://www.youtube.com/watch?v=7MxxaYgEJ8E (https://www.youtube.com/watch?v=7MxxaYgEJ8E)

Title: Re: 1986 Countach Replica
Post by: Correy7 on November 08, 2017, 03:34:15 PM
Thanks - that was a late night post, appreciate the rotation  ::thumbup
Title: Re: 1986 Countach Replica
Post by: 01Lambiero on November 10, 2017, 07:23:43 AM
Please note the headliner repair videos in my previous post.
01
Title: Re: 1986 Countach Replica
Post by: 88.5countach on November 13, 2017, 11:57:24 AM
01 - success! With a little elbow grease, multiple curse words and a few lucky bounces I was able to remove door cards, remove struts and replace with new 4775's that were easy to order at Lordco (same day). The doors function 100% better than before, I am really impressed! Thank you again for the guidance fellas, saved me many $$ along the way!

Not to mention, the car was missing the key for door locks when it arrived here in Vancouver, the seller did not have a copy, lo and behold the original key must have been forgotten in the door during the build as I found it in a pile of dust in door interior  when replacing the strut ..I was pretty happy about that, one last thing that would have needed to been replaced! I.e lock cylinders

Next up: headliner repair, front latch repair and last but not least , washer fluid pump attention.

See picture for outcome of strut replacements!

Front latch is it no latching closed or you can't open it?

For the washer fluid, think its in the front but you can always follow the nozzel line from the wiper area into the compartment and trace it that way. 

TS
Title: Re: 1986 Countach Replica
Post by: Correy7 on November 13, 2017, 01:33:36 PM
TS -

I was able to get the front latch opened finally, it is an electrical latch however the switch under the bumper appears as though it is not functioning, I was however able to circumvent this by running 12v directly to the switch. The question now is do I try and rewire or simply replace with a mechanical latch, the latter seems more practical. I am going to get a test light though to determine wether it is a faulty switch or feed first, this will influence my decision.

Regarding the wiper issue - this is a bigger can of worms then I was initially expecting...

The car does not have a reservoir... the fluid line that runs from the wiper cuts off just under the hood  :'(

So I am starting from scratch on this endeavour, my first thoughts are:

1. Purchase a used reservoir/pump
2. Mount within interior steel frame
3. Figure out how to wire pump....I have looked fiero at wiring schematics and it appears as though the pump is wired to the wiper motor...does anyone have insight or picture / schematic reference for an 86 fiero? Does not seem as though the physical component of adding the reservoir, pump and line will be difficult...the challenge for me will be the electrical end.

Thanks all!
SC
Title: Re: 1986 Countach Replica
Post by: RT on November 13, 2017, 02:21:42 PM
Correy7...
As for the front trunk latch, it is up to you if you want an electrical switch or mechanical latch but if you go mechanical, I would mount a pull cable inside the car with its wire and housing snaking their way up to the latch.  That way the car has to be open (unlocked) for anyone to use it.
The washers are usually wired up with the wipers because when you activate the washer you want the wiper to make a swipe or two to clean the windshield.  That is why you see it wired up to the wipers.  The reservoir can be almost anything from any car as long as it fits your space.  They commonly use a small motor pump with just a hot wire and a ground wire.  Simple to hook up.  The motor is usually mounted on the plastic reservoir and you just press the hose that goes to the windshield squirters onto the outlet port.

RT
Title: Re: 1986 Countach Replica
Post by: Correy7 on November 17, 2017, 11:24:34 PM
RT - really appreciate the insight thank you.

I have disconnected the electrical actuator and am in the process of snaking a pull cable through to original hood release switch just under interior dash.

Further progress, I have removed all reminents of previous headliner material and am awaiting receipt of new headliner for mounting.

Also, 86' Fiero washer reservoir and pump are on their way to my door.

Question:

I cannot locate any diagrams as to where and how the hot wire on washer pump connects to washer motor module. Motor and module appear to be stock, would anyone have a diagram or picture reference that would assist me?

Cheers,
SC
Title: Re: 1986 Countach Replica
Post by: diablodoc on November 19, 2017, 02:13:44 PM
This is the wiring diagram for the Fiero wiper/washer system.
Title: Re: 1986 Countach Replica
Post by: Correy7 on November 19, 2017, 05:09:43 PM
Fellas,

Sincerely appreciate the wiring diagrams and advice - I expect the washer reservoir will be here mid week and will have time to install next weekend hopefully. Will update along the way.

Progress this weekend:

1. Headliner has been repaired, not in necessarily the most aesthetically pleasing sense but it will now clear BC safety as it is not impeding vision. 3M adhesive spray and steel wool did the trick to remove foam residual from prior liner.

Next up:

1. While taking the car on tour in the parkade we lost ability to shift into all forward gears with only reverse working  :'(...

Initially i believed it to be an issue with the gear shift itself but after disassembly of console itself, this did not appear to be the issue.

I checked the cables through to gear box and low and behold I found the issue, the previous owner had taped a piece of copper tube around cable towards end linkage as I suspect the original broke... with heat when running engine as of recently I believe the tape melted which loosened the band aid repair job... I couldn't believe it.. I had this vehicle inspected by a mechanic in New Brunswick prior to purchase...I would think that this should have been addressed then! Oh well, a few issues will keep me busy I suppose.

Question I'd like to pose to the group:

1. How do I determine wether this is the selector cable or shift cable?
2. Is it possible to replace end component of linkage or does the entire cable need to be stripped out and replaced?
3. If answer to (2) is yes, any insight that can be offered as to proper steps in replacement, linkage seems easy enough but I am sure there are other factors to be aware of.

As always, thank you!!
Title: Re: 1986 Countach Replica
Post by: 88.5countach on November 20, 2017, 12:52:04 PM
TS -

I was able to get the front latch opened finally, it is an electrical latch however the switch under the bumper appears as though it is not functioning, I was however able to circumvent this by running 12v directly to the switch. The question now is do I try and rewire or simply replace with a mechanical latch, the latter seems more practical. I am going to get a test light though to determine wether it is a faulty switch or feed first, this will influence my decision.

Regarding the wiper issue - this is a bigger can of worms then I was initially expecting...

The car does not have a reservoir... the fluid line that runs from the wiper cuts off just under the hood  :'(

So I am starting from scratch on this endeavour, my first thoughts are:

1. Purchase a used reservoir/pump
2. Mount within interior steel frame
3. Figure out how to wire pump....I have looked fiero at wiring schematics and it appears as though the pump is wired to the wiper motor...does anyone have insight or picture / schematic reference for an 86 fiero? Does not seem as though the physical component of adding the reservoir, pump and line will be difficult...the challenge for me will be the electrical end.

Thanks all!
SC

See if you can find a diagram for the shift cables online.  Picking up one of those service manuals is a must, it will tell you step by step, it will always come in handy.  Since one cable went, there is a good chance the other may be at the end of its life, so I would suggest you do both, (your their).  Good thing is you now know how to get at both ends hopefully there is access to any cable mounts there may be between the two ends.  Hopefully others building with Fiero's can help.
Title: Re: 1986 Countach Replica
Post by: 76mx on November 20, 2017, 08:54:12 PM
Sounds like they spliced and lengthened the cables when they lengthened the chassis, and did a poor job of it. $200 will get you two new cables the correct length at Control Cable Inc. 562-949-0455, talk to Greg.
Title: Re: 1986 Countach Replica
Post by: Correy7 on November 21, 2017, 01:33:24 AM
Fellas -

As always appreciate the insight -

Was able to find an 86' Fiero Haynes Service Manual on EBay for next to nothing, great suggestion, I would have never known something of the like existed otherwise.

Lots to work on for a few weeks now, I'll keep this thread up to date as progress is made or challenges come up.

Thank you again!
Title: Re: 1986 Countach Replica
Post by: Correy7 on December 12, 2017, 06:40:28 PM
Fellas,

Great news to report and will update with pictures if interested later this week.

Purchased an 86' Fiero washer fluid reservoir and pump via EBay, installed in front compartment (mounted on subframe assembly), wired off primary harness (thanks to the help of members pointing me in the right direction with diagrams) and plumbed...it may seem small but pretty rewarding to now have a fully functioning wiper assembly!

Next up: shift cable and shifter assembly.

Question: Would anyone have a lead on a shift gate similar to that of the FiEuro product?I know Rodney Dickman offers the improved shifter but am having difficulty finding a gate (for aesthetic purposes only).
Title: 1986 Countach Replica: Progress Update & Inquiry
Post by: Correy7 on March 03, 2018, 06:58:57 PM
I am now just a few repairs away from clearing the British Columbia safety inspection, the remaining to do items are:

1. Front hood electrical latch needs to be re-wired or replaced, does not function atm. Looking like this will be a straightforward fix.

2. Driver and Passenger seats need to be secured, original fiero set was extracted by previous owner and replaced with racing seats....bolted directly to floor pan. Is this common practice? I am contemplating installing seat tracks and brackets for ease in re-positioning. Problem with existing situation is that they are not secure... there is a marginal amount of play when tested.

3. **Not a safety requirement however under progress now, I am replacing the muncie 4spd shift cable, purchased new one from Rodney Dickman and awaiting arrival of the sport shifter Rodney produces to replace the existing shifter which is aesthetically hard on the eyes. 


Inquiry:

1. The door glass on my car is a solid piece with bracket layover to mimic the split window look of OEM (i.e bottom half does not roll down). on top of this, it appears that my cooling system is kaput i.e. AC brings in marginally cooler air. I am looking for ways in which other owners have brought in outside air into the cabin to ensure I do not bake like a lobster. When thru vents are opened they still brings in very warm air, largely due to the fact that they lie right behind the rad in the front compartment... would anyone have ideas as to how best to tackle this issue. Cabin interior and cooling system are stock 86' fiero, I am looking for a relatively easy solution as opposed to an overhaul of the AC system.

As a thought, I am mechanically inclined but still new to this hobby... could clogged air filters be contributing to this issue?
Title: Re: 1986 Countach Replica
Post by: 88.5countach on March 05, 2018, 10:31:25 AM
Sorry been away from the site a while.  I'm wondering if when the blower is on it is still getting hot from the heater core.  You need that for defog but wondering if you bypass the lines to the blower box if it makes any difference.  Just a thought, the fiero guys may know better.  My thought is to loop the hot out line from the engine to the heater box to the return line from the heater box on the engine.  Then you know for sure there is no heat in the blower box.  But I think you'll need it for the defog.