Kirkham Motorsports Assembly Manual

[David Kirkham]

Now clean EVERYTHING off with lacquer thinner or something else that removes grease. I guess I should tell you that lacquer thinner is EXTREMELY flammable and the fumes can make you sick so make sure you do this in a well ventilated area (or better yet, get a buddy to do it for you while you graciously offer to go out and get some cold ones...)

[David Kirkham]

Time to whip out the silicon. If you notice, we use the same silicon everywhere in the car. It just makes it easier to do things.

[David Kirkham]

Just a SMALL bead of silicon! Don't make a mess and make your car look like a Z06 Corvette! Have you ever seen the underside of a VETTE?!?!? WHAT A MESS! They could save 50 pounds on the vehicle if they would just be more careful with the goo. It looks like Carlsbad caverns when you look under there...stalagtites everywhere.

[David Kirkham]

OK, OK,

I figured some of you Corvette lovers out there might not believe me...so I had to post a pic of the undercarriage of my car...wait a minute...did I just come out of the closet?

See, just like Carlsbad Caverns. No wonder GM is going bankrupt. Toyota would NEVER let this happen.

[David Kirkham]

Now put the shift box back on...only this time, make sure the lever is in the FORWARD position!!! Or, you will wonder why the hole in your tunnel doesn't line up.

[David Kirkham]

Clean up the silicon so you don't look like a pig. (Or a VETTE)



Now is a good time to put oil in the tranny. It is WAY easier now than it is trying to do it while you are on your back under the car. Of course, that is a good way to get a face full of oil and I hear some people are really into being covered in oil...

This is what we use. Dextron III Mercon.



NOTE:

If you are really observant, you will notice the back grounds are different in the pictures. The problem is, my guys put cars together faster than I can take pictures and post them so you are actually looking at two different cars.

Just dump it in. The tranny takes slightly less than 3 quarts. We usually just dump in 3 quarts, however.

[David Kirkham]

Remember this pin??? We need it now. Drive it out and put it into...

[David Kirkham]

your new billet stainless shift lever. See, even Sandwich is smiling because he makes such cool parts...or, maybe it was that longgggg lunch...

[David Kirkham]

Put the 1/2 ball back on the shifter.

[David Kirkham]

Interesting...do you see the numbers written on Sandwich's gloves? Those are CNC coordinates for making the shift lever.

[David Kirkham]

Grease up the shift lever. And put the lever back in the socket.

[David Kirkham]

Make sure the ball on the lever goes all the way through the rubber grommet.

[David Kirkham]

Put the assembly back in the shift box. Notice Sandwich has already put the far spring wear button back in.

[David Kirkham]

Put the wear buttons that go under the springs back in FIRST and then put the small spring in--centered over the little boss on the wear button. The little nub should fit right into the spring so it doesn't move around while you are grinnin', hangin' on, and grabbin' gears.

[David Kirkham]

Then the large springs go on OVER the small springs.

[David Kirkham]

Then bolt the straps back down.

[David Kirkham]

Now put the rubber boot back on.

[David Kirkham]

Now you can put the shift knob on and pretend you are Bobby Rahal, Mario Andretti, Jeff Gordon, or Michael Schumacher.

Remember to take the knob back off before you put the shift boot cover on or you will tear the boot and be very unhappy.

Your Chariot of Fire is now 1 step closer...

[David Kirkham]

Now it is time to save that beautiful body from road gators, rocks, and gremilins flying up off the road. You know, the ones that like to make the little "outy stars" on the original cars? Well, we glue in 3/8 inch thick black, closed-cell foam. I have had mine on for 9 years now and I haven't had a single dent from a rock being thrown up into wheel well.

[David Kirkham]

This is some of the stinkiest stuff ever created on earth. I personally HATE the stuff...but man does it stick! We have tried everything and NOTHING sticks like this goo.