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AK Sportscars AK 427 Build Manual

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Summary of Contents for AK Sportscars AK 427

  • Page 2 DEAR FELLOW ENTHUSIAST CONGRATULATION`S ON YOUR CHOICE OF AN AK 427 COBRA KIT. THE AK 427 WAS INTRODUCED IN 1990 AND IS THE RESULT ENTHUSIASTS LIKE YOURSELF WANTING TO SEE A QUALITY PRODUCT THAT WAS STRONG WITH A FLEXIBILTY OF BUILD ENABLING THE USE OF DIFFERENT ENGINE GEARBOX COMBINATIONS COMBINED WITH THE STRENGTH AND RELIABILITY OF JAGUAR RUNNING GEAR.
  • Page 3 INTRODUCTION WE WOULD ADVISE THAT YOU READ THIS BUILD MANUAL IN ITS ENTIRETY SO AS TO FULLY FAMILIARISE YOURSELF WITH THE CONTENTS HEREIN. ALTHOUGH EVERY EFFORT HAS BEEN MADE TO APPROACH THE BUILD COMPREHENSIVELY, THIS IS NOT A DIFINITIVE WORK AND IS INTENDED AS A GUIDE WITH WHICH TO ASSIST AND ADVISE YOU DURING THE BUILD PROCESS.
  • Page 4 CONTENTS CHAPTER ONE…………. Your AK 427 Specification Engine and Gearbox options AK 427 Kit contents Optional Parts Manufactured by AK Donor list Parts suppliers list and approximate costs CHAPTER TWO…………. Preparation Safety Tools Workarea CHAPTER THREE……… Chassis/Body Chassis support and preparation Body storage CHAPTER FOUR…………...
  • Page 5 CHAPTER EIGHT……….. Body/Fitting Preparation/fitting body Roll bar & seatbelt brackets Windscreen Door locks Screen washers Boot Hinges/locks/bonnet stays Lights/Head /Indicators/Brake/Number plate Petrol filler/Pipework Nudgebars/Overriders Seatbelts CHAPTER NINE…………. Cockpit/components Mechanical Pedal box assembly Steering column Handbrake Heating system Wiper motor/wipers Instrument panel/instruments/Switchgear CHAPTER TEN……………...
  • Page 6 AK for correct OFFSET. ENGINE & GEARBOX APPLICATIONS GENERAL INFO………….. The AK 427 is designed to accept various Engine and Gear box combination`s, listed below are some that have been applied previously to the AK chassis,and have proved to be reliable,easily fitted and giving excellent performance in keeping with the concept of the original.
  • Page 7 YOUR AK 427 ENGINES………………….. ROVER V8, 3500cc/3900cc/4200cc/4500cc/5000cc/6300cc Although expensive to tune in its standard forms ie 3.5ltr 3.9ltr and 4.2ltr this is a very capable engine of light weight compared to alternatives and extremely reliable with an output of 165bhp to240bhp,the tuned versions of all the...
  • Page 8 YOUR AK 427 LEADING DIMENSIONS & DESIGN WEIGHTS AK 427 DESIGN WEIGHTS. AXLE 1 638 kg AXLE 2 780 kg GROSS 1400 kg...
  • Page 9 YOUR AK 427 AK 427 KIT CONTENTS CHASSIS…………………………Ladder type with partial backbone and full steel lowered Floors BODY…………………………….Finished in white gel coat,(colours optional) • scuttle hoop bonded into full inner tub • body temporarily bolted to chassis • doors and bonnet pre-hung •...
  • Page 10 YOUR AK 427 OPTIONAL PARTS SUPPLIED BY AK (all prices plus VAT) COIL OVER SHOCKS (6 of) PETROLTANK STAINLESS STEEL (14 gall) HEADER TANK (stainless steel polished) WASHER BOTTLE (stainless steel polished) REAR WHEEL ARCH STONEGUARDS (stainless steel) SIDE VENT`S (stainless steel)
  • Page 11 YOUR AK 427 DONOR PARTS LIST JAGUAR POST 1974 ( VENTILATED FRONT DISCS) FRONT AXLE GET SCRAP YARD TO CUT OFF COMPLETE SUBFRAME REAR AXLE COMPLETE ON SUBFRAME RATIOS 3.54:1 For 3500 Rover engine 3.31:1 Larger capacity engines 3.07:1 For 4 speed gearbox 2.88:1...
  • Page 12 CHAPTER TWO PREPARATION SAFETY………………….. There are many dangers in the workshop,we cannot stress enough the need for safety, you need to be aware of the inherent hazards surrounding you whilst building and stripping mechanical components and in using electrically operated power tools. REMEMBER…...
  • Page 13 DUST. Can cause irritation to the eyes and skin, block nasal passages and cause respiratory Problems clean all work area after working with GRP. ie. After sanding, cutting and Drilling. EYES. Wear protective eye glasses whilst carrying out operations with electrical tools, such As grinding, drilling, sanding.
  • Page 14 MISCELLANEOUS…….. tape measure/ruler , spirit level , marker pens, masking tape. SPECIAL TOOLS…… pullers, spring compressors ( Hire shops are good source for these) WORKSHOP/GARAGE. Working on or around the vehicle requires space, a double garage is preferable but not available to all, so consider your work area and storage facilities, room to lie on the floor and stripping down of donor parts and storage of same.
  • Page 15 You will have also receive other items necessary for your build, namely nudge bar brackets, shortened wishbones, roll bar brackets, various nuts and bolts for body to chassis fitment. A full list can be seen in the chapter <YOUR AK 427>. SUPPORTING CHASSIS.
  • Page 17 You also need to take the final drive ratio into consideration and check it is suitable for your engine/gearbox combination, refer to information in chapter <YOUR AK 427>. FINAL DRIVE RATIO determines the acceleration and maximum speed of the vehicle, a high figure (ie, 3:54:1) gives faster acceleration but lower maximum speed, a low figure (ie 2:88:1) gives lower acceleration but higher maximum speed.
  • Page 18 The suspension components are mounted in subframe assemblies, you need to remove these from the donor vehicle first, then remove the suspension components and brake components from subframes, rusted nuts and bolts are best soaked overnight if possible with penetrating oil or similar to aid the strip down procedure, wire brushing around nuts bolts and threads will aid removal and make the task a lot easier.
  • Page 19 NOTE: remove the top centre bushes from the rear shock absorbers, you will require them for fitment of the front shock absorbers when rebuilding. Keep the shims from drive shafts to disc, as these are required for camber set-up, and the shims from the inner pivot mounting.
  • Page 20 CHAPTER FIVE CHASSIS BUILD : IMPORTANT : THE INFORMATION REGARDING REBUILDING AND REFURBISHMENT OF SUSPENSION COMPONENTS IS FOR GUIDANCE ONLY, YOU MUST REFER TO THE RELEVANT JAGUAR WORKSHOP MANUAL AS THE MAIN REFERENCE FOR THE REBUILDING PROCESS AND TORQUE SETTINGS FRONT SUSPENSION / REBUILD AND FITTING.
  • Page 21 (fig 5.1)
  • Page 22 (fig 5.2) Fit complete upper wishbone to AK chassis at the mounting point toward front of chassis into the bolt holes provided; remember to use camber shims (saved from stripping front suspension) between pivot arm and chassis; (fig 5.3) (fig 5.3) Fit lower wishbone arm to chassis mounting point (these are handed, check and fit to correct side), (lower balljoint hole cranked forward).Fit bottom/lower ball joint to stub axle/hub carrier, which in turn is then placed between upper and lower wishbones (remember to use...
  • Page 23 Next the brake caliper and steering arms (note; bolts thru caliper and steering arms need to be wire locked). Attach supplied track rod ends to steering rack which has been pre-fitted to the AK chassis, and then attach to steering arms fit and tighten bolt. Repeat procedure for other side.
  • Page 24 (fig 5.4)
  • Page 25 It is important to note the rear brake discs need to run centrally through the brake calipers, this can be achieved by the use of alignment shims between the differential output flange and the inner mounting face of the brake disc, a trial fit is necessary and is achieved by temporarily fitting and removing brake caliper and brake disc and packing with alignment shims until the brake disc runs centrally through the brake caliper, once this has been achieved the brake caliper can be permanently fastened into position, (remembering to wire lock the bolts into...
  • Page 26 (fig 5.7)
  • Page 27 Camber shims (which have been saved from stripping rear suspension) will now need to be inserted between the outside face of the brake disc before fitting the driveshafts and driveshafts secured to the disc/differential output flange mounting bolts with new nyloc self locking nuts. Hub carrier assembly can now be put into position on wishbone outer pivot using nyloc self locking nuts on outer pivot shaft, hub carrier assembly can be pivoted upward and splined yoke from drive shaft inserted, torque driveshaft locknut to the specified torque.
  • Page 28 SUSPENSION SETUP INFORMATION The adjustment of the Jaguar suspension as used on the AK 427 is enabled by the use of metal shims, the process is referred to in the jaguar workshop manual, the instructions as to set-up as Contained in this section are specific to your AK 427 All adjustments/settings to the front and rear suspension are to be carried out with the chassis Completely levelled fore and aft and side to side.
  • Page 29 raise or lower the hub carrier until this is achieved. Place a spirit level or the gauge against the face of the hub, (fig 5.10) at the correct setting this needs to be 0 degrees to ¼ degrees negative camber, to adjust this measurement shims need to be inserted between the the drive-shaft flange and the brake disc/diff output flange, using two nuts on the bolts which hold the driveshaft to the disc / diff output flange screw these down on the threads pulling driveshaft closer to the disc until the desired measurement is achieved at the hub face,...
  • Page 30 the correct thickness between the upper wishbone pivot/fulcrum shaft and the wishbone attach- ment point on the AK427 chassis. SETTING/ ADJUSTMENT CASTOR To set the castor angle to the front suspension is accomplished with the use of shims between the mating faces of the top balljoint and the upper wishbone with track rod ends removed, raise the wishbones with hydraulic jack so they run level/horizontal slightly lower than level, (fig 5.11) (fig 5.11)
  • Page 31 (fig 5.14) repeat process for the other side, re-attach track rod ends and locknuts ensuring equal thread both sides, toe in can be adjusted temporarily at this stage by raising wishbones hub assembly as before until both sides are level/horizontal and adjusting track rod ends equally until both disc/hub assemblies run straight ahead.
  • Page 32 BRAKE LINES/HOSES INFORMATION. Reference to the workshop manual is essential when reconditioning all brake components, if in any doubt consult qualified specialist help. DUE TO THE PERFORMANCE CAPABILITY OF YOUR AK IT IS ESSENTIALTHE BRAKING SYSTEM IS ABLE TO FULFILL THE TASK AND THE DEMANDS MADE OF IT. At AK we use and recommend the use of new and reconditioned brake components, DO NOT just use the brake components as they came off the donor, considerable wear will almost definitely have been incurred.
  • Page 34 Use the correct pipe-bending tool and cutting and flaring tool. Using a piece of string to measure approximate length of brake pipe needed cut to length remembering to file away any burrs, Place appropriate fitting/union over brake pipe and make appropriate flare dependant on fitting type.
  • Page 35 (fig 5.16) (fig 5.17)
  • Page 36 DO NOT run brake lines under chassis rail so as to prevent damage in the event of the vehicle grounding out ie: sleeping policeman :IMPORTANT: WHEN BRAKING SYSTEM IS FULLY INSTALLED IT MUST BE TESTED FOR LEAKS AT ALL CONNECTIONS WHILST APPLYING FULL PRESSURE TO THE BRAKE PEDAL.
  • Page 37 FUEL PUMP AND FUEL LINES INFORMATION Dependant on fuel system ie: carburettor or fuel injection type of pump and were to mount will need to be taken into account. With fuel injected systems it is important to mount the fuel pump as near to the fuel tank as possible and to use a high pressure fuel filter, preferably the one that came with fuel injection system, high pressure fuel hose will be required as the pressure from the pump will be 60 psi on average, normal fuel hose is not rated at this pressure, use hose specific to...
  • Page 38 (fig 5.20) A protective plate will net to be fitted to the underside of the differential to protect the fuel line in the event of the vehicle grounding.
  • Page 39 CHAPTER SIX ENGINE/GEARBOX/EXHAUST/PROPSHAFT GENERAL INFORMATION. Your chassis is now ready to accept the installation of your choice of engine and gearbox, although it is possible to fit said items once the bodyshell has been introduced to the chassis, it is preferable to install the engine and gearbox now, which in turn eases the installation of all of the necessary ancillary components, when ordering your chassis you will have specified engine and gearbox choice, the chassis will...
  • Page 40 :IMPORTANT NOTE: CLEARANCE OF STEERING COLUMN EXTENSION / FOOTWELLS AND STARTER MOTOR SHOULD BE TAKEN INTO ACCOUNT WHEN ASSESSING THE MEASUREMENT AND INSTALLATION OF EXHAUST HEADERS/SYSTEM UNDERFLOOR SYSTEM. If fabricating your own headers/manifolds or using aftermarket fabrication company, In order to ascertain the clearance for headers/exhaust manifolds/system you will need to place bodyshell onto chassis after installation of the engine to take measurements, remove bodyshell to fabricate Header/manifolds...

  • Page 41: Cooling System

    CHAPTER SEVEN. COOLING SYSTEM. INFORMATION. The cooling system incorporates a crossflow radiator (Rover SD1) a header tank which is uses a pressurised cap and the system should have a thermostat with which to control the temperature at the same to as allowing the engine to reach its optimum operating temperature . The coolant circulation is from a pulley driven impeller at the front of the engine driven by the crankshaft pulley .
  • Page 42 (fig 7.1) HEADER TANK Header tank is mounted onto the same box section as the upper radiator frame , after first placing strips of masking tape along top rail position header tank on top of rail and mark the attachment holes onto the masking tape , drill and tap these holes remove the tape and replace header tank and bolt into place .
  • Page 43 HOSES Finally fit the coolant hose top and bottom check for fouling on any moving part, ensure all hose clips are fastened securely , leave extra length on heater hoses until after body is fitted and these can then be trimmed and attached to the heater inlet and outlets, run a thin bead of silicone sealant around heater outlets before attaching hoses enabling a greater seal.
  • Page 44 CHAPTER EIGHT. BODYSHELL/FITTING INFORMATION. The AK body is supplied with the cockpit (seat tub) / boot tub/ front & rear wheel arches bonded into the shell as an integral part of the whole assembly, doors and bonnet are pre-fitted and the bonnet and boot lid and doors all are double skinned, a scuttle hoop is mounted within the seat tub and spans across the seat tub under the dashboard it is bonded into place and once the body shell is fitted it is through bolted onto chassis.
  • Page 45 (fig 8.1) FITTING BODY Once you are satisfied with the preparation of the body and ensured all access holes are cut and the required parts attached (pedal box / heater) and having undergone a trial fit to establish clearance, you can now fit the body to the chassis. It is necessary to run a bead of sealant along the chassis rails were the seat tub sits and also across chassis cross member were roll bar and seat belt brackets attach and around fuel tank support rails, first clean the chassis were sealant is to be laid then run a ½...
  • Page 46 (fig 8.2)
  • Page 47 ( fig 8.3) ( fig 8.4)
  • Page 48 FITTING OUT THE BODY ROLL BAR and SEAT BELT BRACKETS INFORMATION The seatbelt and roll bar brackets supplied with your kit are supplied in 3 or 4 parts depending on your choice of roll bar whether it be single hoop drivers side/ twin hoops both sides or full width hoop variety.
  • Page 49 First fit will be temporary as you need to mark and make the holes for the seatbelt attachment eyebolt to attach to, the hole is made under the scuttle lip at the rear of the cockpit/seat tub, to do this place the right hand seat belt bracket in place on the raised platform in the boot, insert the bolts through the brackets base plate and the fibreglass skin into the chassis below, from underneath the vehicle put on at least two of the nuts and tighten so as to hold bracket in place whilst marking the positions of the seatbelt eyelet bolts.
  • Page 50 ( fig 8.7) Repeat for the passenger side. The roll bar support bracket is a simple matter of bolting into place after checking the alignment of the chassis mounting holes through the fibreglass skin. (fig 8.5 /6) ROLL BAR/s INFORMATION The roll bar for the AK is made of stainless steel tube bent to form a hoop, were as this was a support and safety feature in the original, for our purposes the roll bar is purely cosmetic, one or two roll bars can be fitted as is your preference.
  • Page 51 WINDSCREEN INFORMATION The windscreen is purchased as a complete assembly, furnished with glass pre-fitted to the frame and held in place by a rubber seal, support legs are to be found at either side of the wind- screen with which to attach it to the vehicle, there is also a rubber seal along the bottom edge of the windscreen were the frame makes contact with the body, the windscreen is fitted to the scuttle and is supported/attached by the support legs through holes in the body to the scuttle hoop.
  • Page 52 ( fig 8.8) Once the screen is in place put the piece of timber cut to 36 inches length between top wind- screen frame and scuttle lip at rear of cockpit, using G clamps or similar clamp support legs to scuttle frame under dashboard scuttle.
  • Page 53 fig 8.10) Bolt the windscreen into place and remove piece of timber used for measuring windscreen rake and G clamps, the screws attaching windscreen to support stays can be removed now and windscreen removed from between stays to allow the escutcheon plates to be pushed down the support stays to cover the body holes were support stays pass through, it is advisable to put some sealant in the support stay hole before fixing escutcheon into place to prevent the ingress of water at this point, re-attach windscreen remembering to pull rubber seal at base of windscreen...
  • Page 54 DOORS INFORMATION The doors on the AK are double skinned and pre-fitted by AK at the factory, they are hung on two hinges which are attached to the scuttle hoop, two bolts to each hinge fasten to the inner door skin and allow some adjustment. the mounting plate for the door locks is already incorp- orated inside the door skin for the door locks.
  • Page 55 If the door lock is to sit on the door panel (AK preference) then a spacer or the door panel will need to be used to position lock onto the door remembering that the thickness of the panel will be plywood panel the padding and the leather covering, this will determine the thickness of the spacer if not using the covered door panel as the spacer.
  • Page 56 With the door lock now attached bring door into closed position once again to position the latch, with the latch in position in the lock (ensure it is fully engaged) attach the latch mounting plate to the latch and door frame, once satisfied with its position fix into place using p38 and leave to set.
  • Page 57 is part of SVA regulations and compulsory in the UK that a windscreen washer system is fitted and working to your vehicle, the washer jets also need to comply with the regulations re: there curvature and height, the fluid container as to its capacity ie: minimum of 1 litre. PARTS REQUIRED Washer bottle/container (AK can supply a stainless steel item if required) Washer jets x 2...
  • Page 58 BOOT LID A trial fit of the boot lid is necessary to adjust for an even gap all around, (fit the d-section rubber to the boot lid opening first and ensure that the boot sits level with the bodywork) you may need to file down the lip to achieve this.
  • Page 59 There are small locating tabs in the escutceon/baseplate of lock which will require small notches to be cut/filed into the lock hole you cut, this helps to locate the lock into position. ( fig 8.15) To ascertain the position up the centre line for the hole, trial fit the lock assembly to the access hole in the boot lid, (the access hole may need opening out/modification) ensure the square hole in the lock for the shaft to pass through is in line with the centre line of the boot lid, which will then line up with the holes for the boot handle square shaft.
  • Page 60 BONNET The bonnet on your AK has been pre-fitted originally at the factory, however you will have removed it during the build, replacement is just a reversal of the removal procedure but you will need to before fitting the d-section rubber seal to the bonnet opening file or cut down the lip that the seal attaches to, trial and guesswork will be required to gauge the correct height that will allow the bonnet to sit level with the bodywork.
  • Page 61 From the under side of the bonnet you will need to fit the locking catches to the square shafts of the bonnet locks (these are locked in place with small allen screws) (fig 8.16) The square shaft will need shortening once the latch position has been found. In order for the locks to full engage securely it will be necessary to fit locking plates (fabricate with some stainless steel) these bolted to the bulkhead under the scuttle in the engine bay and provide a stronger closure/attachment for the lock.
  • Page 62 FITTING Offer up the gasket from the fuel filler cap to the recess in the drivers side wing, centralise the gasket the mark the inner circumference with a marker pen, if you have a hole saw large enough this can be used, alternatively drill several pilot holes inside the circumference line previously marked, using a saw cut between the holes inside of the line, using a half round file open up the hole to the line, offer up the fuel filler to check for clearance, once filler inserts into hole the filler can be fitted to the recess after marking and drilling the fixing holes using the filler flange as the...
  • Page 63 LIGHTS The AK 427 light positions are moulded into the body shell except for side repeater/indicators and rear fog lamp, it is mandatory for any motor vehicle used on the public highway to be fitted with the appropriate lighting.
  • Page 64 Front position side lamps x2 Dipped beam headlight Main beam headlight Direction indicators Hazard warning signal lamps (as above: indicator lamps) Rear position tail lamp Stop lamp Side repeater lamp Rear registration plate lamp x1 Rear fog light Rear retro reflectors. As can be seen from the list the main lighting positions are moulded on the body shell, the builder needs to be aware that the rear indicators are positioned above the brake/sidelights and side repeaters just above and in front of the side vent in the front wings.
  • Page 65 OVERRIDERS/NUDGEBARS INFORMATION Mounting brackets are supplied to fit the front overrider`s to the chassis, New type fits directly to front inner wings. Older type the brackets attach to the chassis mounting either side of the radiator ,when positioned they angle downwards from the chassis, the rear mounting points are in the boot just inside the boot shut to the left and right metal brackets have been fibreglassed into the boot floor this is also the case under the boot floor behind the rear valance.
  • Page 66 You can now bolt it into position, (nuts will need to be used both sides of the stud/bracket to clamp assembly securely). (fig 8.21) ( fig 8.21) SVA RADIATOR APERTURE DEFLECTOR As a requirement of SVA regulations the front opening to the radiator is fitted with a deflector wing/bar to prevent injury to persons in the event of an accident, it is a requirement that the aperture is not large enough to allow the SVA testers knee form sphere to pass through, the AK deflector when positioned in the centre of the opening prevents this and also complies with the...
  • Page 67 ( fig 8.22) SEATBELTS The seatbelts for the AK are the 3 point harness variety , and are attached to the chassis rails were they meet the floor toward the rear in the seat tub for the lower attachments, the upper attachment is under the scuttle to the previously fitted eyebolt.
  • Page 68 The lower seatbelt mounts are threaded to accept the fixing bolts, the fixing bolts required are specific to the fitment of seatbelts and are of high tensile steel usually but not always these bolts will be marked with 8.8. The threads for the fixing bolts may need chasing out with a tap of the correct thread to ease the fastening of the bolts.
  • Page 69 CHAPTER NINE. COCKPIT COMPONENTS/MECHANICAL INFORMATION The pedal box and heater box are both fitted to the bulkhead from inside the engine bay, there attachment however is from inside the cockpit, although covered in this chapter, both of these items are best fitted to the bodyshell prior to fitting the body to the chassis. The scuttle hoop under the dashboard area of the cockpit has the attachment points/brackets for the steering column and wiper motor pre-fitted although the steering column bracket is pre - drilled the wiper motor bracket the flat steel plate welded to scuttle on the right is not pre-...
  • Page 70 (fig 9.1) PARTS REQUIRED The rover steering column from your donor vehicle complete with upper attachment bolts and adjustable tilt bracket, lower column support (bracket splined end passes through) and wiring harness for wipers/lights and horn/washers. FITTING The Rover steering column is attached to the two attachment brackets using the existing rover column attachment bolts , the splined end support passes through the hole in the bulkhead and is supported using the mounting bracket/ bush which is bolted to the bulkhead/firewall in the engine bay.
  • Page 71 fig 9.2) FITTING The bracket is attached to the offside outer chassis rail just above the seat belt mounting bolt hole. There is already one hole drilled in the chassis for body to chassis attachment bolt, place approximately 1.5" to 2" in front of the bolt. Drill and tap chassis M8 / M10, bolt into place. (Alternatively you can drill all the way through the chassis rail and nut and bolt).
  • Page 72 The AK supplied handbrake cable will now require fitting, the adjustment end toward calipers, a hole for the cable to pass through will need to be drilled in the rear of the cockpit wall, pass the cable from under the offside/drivers rear wheel arch through the hole and attach to the handbrake lever assembly, attach the adjustable end to the rear brake calipers, you will also need to secure the cable outer to the underside of the wheel arch using a cable tie so it does not foul on the rear wheel.
  • Page 73 HEATING SYSTEM INFORMATION As with the pedal box it is preferable to fit the heater box to the body before fitting body to chassis, as it is also attached from inside the engine bay. The heating system consists of heater box and matrix salvaged from Volkswagen polo, two windscreen demister vents (it is a requirement of SVA regulations to be able to demist the windscreen).
  • Page 74 Where the heater box mates to the bulkhead DO NOT REMOVE the angled plastic flange from the matrix/mounting face of the heater box case, (fig 9.5 is incorrect) this assembly can be introduced to the bulkhead/firewall from inside the engine bay, it needs to be positioned centrally on the angled face just above the transmission tunnel, mark around the the heater box with a mark-er pen, then put heater assembly to one side, the rectangular outline you have marked now needs to be drawn again 10 to 15 mm inside the original line so as to leave a...
  • Page 75 Next position and fit the demister vents to the top of the dashboard close enough to allow an even coverage to allow the blown air to demist the windscreen (the positions are marked approximately by AK before the body/chassis leaves the factory), slots will need to be cut in the top of the scuttle/dash and fixing holes, using the demister vents as a template place masking tape on the upper dash/scuttle were they are to be placed, mark the slot and fixing holes then remove demister vent and drill and file slots for the air form heater/blower to pass through,...
  • Page 76 WINDSCREEN WIPERS INFORMATION The wiper system for the AK 427 is a three blade system , the system is left hand parking Ie: drivers side. The system must be self-parking, perform a minimum 110 degree sweep of the windscreen, have at least two speeds one of which performs a minimum of 45 cycles per minute to comply with SVA regulations, .
  • Page 77 PARTS REQUIRED ……. Wiper motor (complete with gear if possible) (Lucas or BLMC) Rubber base pad Bracket/clamp Wiper gear (if not pre-fitted to motor) Wiper rack Bundy tubing Wiper wheel boxes x3 Spacer tubing for wheel boxes x3 (rubber hose can be used) Wiper arms x3 (bayonet type 5.2mm adjustable) wiper blades x3...
  • Page 78 Temporarily fit wheel boxes in place, wheel boxes should be positioned with rack at the bottom so rack will run underneath . (fig 9.10) WIPER MOTOR Fit the rack to the wiper motor but do not fit the tubing at this time , the wiper motor complete with rack can be mounted to the plate provided in the upper right hand corner of the scuttle hoop in the cockpit just to the right of the steering column mounting.
  • Page 79 INSTRUMENT PANEL The instrument panel supplied with your AK is constructed of GRP/fibreglass and moulded to fit the bodyshell under the dash/scuttle, it will have come pre-fitted to the underside of the dash/scuttle and is attached with several butterfly nuts and washers. It is complete with an open glovebox, it is also necessary to cut out the steering column aperture, several threaded studs are glassed into the back of the instrument panel with which to attach to the mounting lip provided under the dash/scuttle for that purpose,...
  • Page 80 (fig 9.11) INSTRUMENTS and SWITCHGEAR Most builders will fit a full compliment of gauges/instruments, but the requirements of the law and SVA regulations dictate specific instruments and warning lights are compulsory. Speedometer Brake warning lamp Fog light warning lamp Full beam warning lamp Indicator warning lamp Hazard warning indication lamp...
  • Page 81 CHAPTER TEN ELECTRICAL WIRING LOOM INFORMATION Electrical installation in the AK is a 12 volt negative earth, comprising of a 12volt battery which is to be located in the boot offside recess, an alternator for charging said battery and pre- engaged starter motor, the battery supplies the current to the ignition system lighting and other electrical circuits and provides reserves of electricity when the current consumed by the electrical system exceeds that be produced by the charging system (alternator).
  • Page 82 Warning lights (ignition/brake fluid level/indicators/full beam) Cable ties /cable clips Spade connectors (male and female) Bullet connectors Rubber grommets Loom tape FITTING Lay the full loom out on the floor, although the loom is supplied as one piece it is separated into legs for different areas of the car, using the loom layout diagram and wires list, prepare the loom for fitting to the car by firstly identifying the different legs and label them with masking tape, as the wires are colour coded for each individual item the legs can be identified this way.
  • Page 83 (fig 10.1)
  • Page 84 (fig 10.2) Once all individual legs of loom are to there respective areas the various connections can be made to each component, there are earth connections at various parts of the loom ( BROWN wire) it is important a good clean connection is made for these to the chassis, there is one as part of LEG 6 attach this to the scuttle hoop after first drilling and tapping a hole to attach it.
  • Page 85 BATTERY CABLE The positive (live/red) battery cable runs the length of the vehicle due to the battery being mounted in the boot, as with all long runs of cable it is wise to use a higher amperage of cable to avoid overheating of cable and current drop.
  • Page 86 (fig 10.4) (fig 10.5)
  • Page 87 (fig 10.6)
  • Page 88 WIPER WIRING When using the AK wiring loom it is in some cases necessary to change the pin configuration on the wiper stalk/on-off switch, when an intermittent relay is placed in the relay block of the wiring loom and intermittent is selected on the wiper switch/stalk it causes the fuse for the wipers to blow, to solve this problem carry out the procedure below.
  • Page 89 CHAPTER ELEVEN COCKPIT/COMPONENTS UPHOLSTERY INFORMATION This chapter covers the fitting of your interior carpet/ side panels/door panels seats and dashboard, all these items the trim level is a matter up to the individuals choice, carpet sets can be purchased from a professional carpet trimmer as can the trimming of the seats/door panels/and dashboard be contracted out to an upholstery trimmer.
  • Page 90 (fig 11.1)
  • Page 91 INTERIOR SIDE PANELS The interior side panels supplied with your kit are made of fibreglass and are handed for the left and right sides of the cockpit/seat tub area (fig 11.2), they are screwed to the timber inserts (put in place when the door locks were fitted) they are also held in place by the door opening trim. The trim panels are covered when you fit the carpet or can be carpeted before fitting inside the cockpit.
  • Page 92 CHAPTER TWELVE. FINISHING WHEELS AND TYRES AK can supply wheels and tyres with the correct offset. For 16 inch wheels. tyre sizes Front… 215/55/16 speed rating.. WR or higher Rear … 245/55/16 speed rating.. WR or higher Offset and rim width - Please contact us Front…...
  • Page 93 SUSPENSION The dampers are adjustable on the AK as is the spring setting, the dampers control the bound and rebound which is adjusted by a knurled knob at the base of the damper body fully turn the knurled knob toward the - minus then back toward the + plus, 7 clicks to start with and further adjust to suit the ride you prefer after suspension has settled.