Gatsby Coachwork, Ltd. Original Assembly Manual

GATHERING COMPONENTS

STEP 1

You must first locate an appropriate chassis to begin the Gatsby project. For optimum ride and ease of assembly, we recommend the 1979 through 1982 Ford LTD or Mercury Marquis. Ford and Mercury chassis' of 1972 to 1978 vintage will also work but require slightly different modifications. For those of you who prefer to use GM running gear, the Chevrolet Impala/ Caprice chassis is quite similar to the Ford/Mercury and can be used.

STEP 2

Removal of the body is the next step. Since it is easier to determine the condition of a chassis while it is in running condition, it will be necessary to remove the body from a roadworthy vehicle or one on which the coachwork has been damaged. The body itself is attached to the chassis with only fourteen bolts. As you remove the body, always retain every one of the stock rubber body mounts because you will need them later. If you do not have the equipment or facilities to complete the body retnoval yourself, usually the local salvage yard will help in exchange for some or all of the usable body parts which you no longer need.

STEP 3

These are the parts and hardware you must retain from the body you removed from your chassis:
Wiring harness; Steering column; Brake pedal assembly; Emergency brake assembly; Throttle pedal assembly; Temperature control panel; Save all nuts, bolts, & fasteners

STEP 4

Next, you must remove the following mechanical systems:
The engine/transmission/driveshaft; Brake line (leave brake block on chassis); Fuel line/vent line; Exhaust system

STEP 5

In order to accomodate the Gatsby coachwork, the chassis must be adjusted to a wheelbase of 118.3" As you know, the wheelbase is the distance from the center of the front wheel hub to the center of the rear wheel hub. This procedure requires the removal of the two stock side rails on your chassis (see Fig. 1A). Two new rail sections, each one 73" long, are then cut from 3" x 4" x 3/16" steel tube stock. Install the new side rails in the positions illustrated in Fig. 2A. At this point, be sure to level and diamond measure the entire chassis. All four joining points are ready to gusset and weld. Unless you are a professional welder, it is advisable to have this important chassis modification done by a reputable frame and body shop. With our instructions and diagram, these adjustments can be made in a matter of a few hours.
STEP 6

In order to achieve better weight distribution, it is necessary to install the engine and transmission to the rear of its stock location. For this modification, the stock Ford or Mercury rear cross member may be used (see Fig. 3A). The drive shaft must be shortened to 27" before it can be reinstalled. Be sure to measure the drive shaft from the center of its universal joints. It should be noted here that since there are often minor differences in the drive train componenets, your drive shaft may have to be a bit longer or shorter. After it is shortened, the drive shaft must be balanced to prevent vibration during operation (see Fig. 3A). A top view of the chassis with all componenets in place shows how to locate the positioning of the transmission and engine mounts (see Fig. 3B). You will note that the engine is offset one inch to allow clearance for the air conditioning pump. The engine mount itself can be easily located at your local automotive speed shop. At this point, the brake and fuel lines may be replaced on the adjusted chassis.

STEP 7

Remove front and rear frame horns (see Fig. 4A). Your chassis is now ready for mounting the body.


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