From Bruce: http://home.talkcity.com/FerrariDr/f...5/KitHowTo.htm

F355 Kit installation.
1. You'll need the following tools:
MIG welder, min 110A output
Reciprocating saw (i.e. "SawZall") with bimetal long blands (minimum 5")
3/8" power drill
Grinder (4" disk)
Metric socket and wrench set
Screwdriver set
Tape measure
Marker pen
Jack stands
Hydraulic floorjack
Pliers
Utility Knife

2. Fiero Prep.
Remove the following body panels from the Fiero using a 10mm socket or wrench. Several rivets must be removed by punching in the center of the rivet around the lower part of the rocker panel extending to the front and rear fenders. This application is different on GT Fieros and regular SE bodies, attachment method remains the same however.

Front fenders, hood assembly, (13mm socket), engine cover (13mm) including all associated hinges.

Front bumper cover, rear bumper cover.

NOTE: Remove the sidemarker lights prior to pulling off body parts. The light plug must be turned 1/4 turn counterclockwise to release the bulb.

Remove headlight assemblies, unbolting 4 10mm nuts where magnesium frame attaches to the firewall.

Remove rocker panels, rear quarter glass (both sides), and main rear quarter section. [NOTE: the head-liner must be removed before the roof, and rear quarter sections]

To remove main rear quarter section you must first remove 2 grills on either side of the rear decklid. You must also CAREFULLY remove the fuel filler door and housing assembly which will be reused when assembling the kit. Make sure the gas CAP is replaced after removing the filler assembly for safety reasons. An open gas tank could prove hazardous when performing the stretch and sub-frame welding. [do NOT try welding around an open gas tank!]

Remove the roof panel after releasing the windshield molding first. Molding will be reused at a later stage.

Unhook the left and right radiator hoses at the front end of the hose. Unbolt two (2) cradle front attachment pivot points.

Secure the chassis on a flat surface, with no wheels touching the ground - using four (4) jackstands.

Do NOT support the chassis at any point BEHIND the rear firewall!


3. Stretch
(see Kit Car Magazine, March 1996, article "Hey Stretch")
[NOTE: in the instructions I received, this article was reproduced completely via photocopy]

4. Frame Preparation
After the stretch is complete, install the supplied radiator hose extension pieces. Fill up the cooling system and make the following cut for the roof:

Remove the rear window. Cut off both B and C pillar at the base of each pillar, or the same height as the upper edge of the rear firewall. Place the new F355 kit windshield frame on to the A pillars and using a marker (grease pen, or ‘sharpie’) mark the cut line on the roof - this line is approximately 4-inches from the upper edge of the windshield. Notch the sheetmetal right in front of each headlight as per drawing [?drawing was not included]. This is to allow forward repositioning of the headlights. Remove rear steel bumper as there is no room for it in the kit.

Place the front clip loosely on the car and attach front steel subframe (supplied with the kit) [not in my case] to the front clip. Make sure clip is parallel and straight in reference to the frame. Do not use ground as a reference point because you cannot tell visually if it is truly "level". Make all measurements in relation between the part to be added, and the chassis (which must be level). Weld or bolt the front subframe securely to the chassis. Remove carpeting and center console inside the car. Weld in the center reinforcement frame to the center tunnel on the passenger compartment. Weld at least 2-inch seams with 2-inches of space between seams through the entire length of the reinforcement bar subframe. Recommend spot welding at three (3) points first, measure to insure it’s still straight, and then finish the 2-inch seam welds 2-inches apart.

[NOTE: I welded attachment points to the subframe, and BOLTED it to the center tunnel BEFORE cutting off the roof. Bolting allows you to later remove the subframe in case you need to replace the fuel pump, or gas tank.]

Repeat the same steps when welding both side rocker panel reinforcements as per drawing [no drawing]. Check for labels attached to parts in the kit to verify the right and left side [no labels on my kit].

These changes will require you to use a different center console from the original Fiero console. The interior is optional with all 355 kits.

Clean and paint the frame or weld/cut areas for appearance/protection. Relocate the doorhandles as per drawing [no drawing]. Cut hole into doors to allow doorhandles to come through at appropriate place in the air intake duct in the door as in the drawing [no drawing].

5. Mounting the kit body
To start, mount all body panels loosely, using weld clamps, or C clamps to give you a visual idea where parts are supposed to go and to see how the bodylines will match up. Mark the approximate lines for the height of the door panel attachment but observe the inside shape of the door. Make sure it fits flush with the shape of the metal door. No gaps wider than ¼-inch are acceptable. Mount both side doors ensuring they are exactly the same height and distance from all points of measure. Left side of the car has to be a mirror image of the right side of the car. After doors are securely attached either using bolts, pop rivets, sheet-metal screws, or any other attachment method you feel secure with, attach the front clip matching the bodylines at the end of the front fenders to lines at the front of the doors. Attach the front clip to the car with OEM 10mm bolts and use bolts or rivets to mount clip to the front subframe. Weld two (2) reinforcement bars as per video [video tape was nicely boxed, but tape was blank]. Weld rear inside fender reinforcements into place and bolt or rivet body panels to the bars. Make sure all parts fit completely free and stress free. Secure with clamps to hold it in place prior to welding. Using hinges supplied with the kit, mount the hood and engine cover as per video. Remove the catchhooks from respective fiero parts, and mount them to the corresponding kit parts. The engine cover latch should be mounted to the frame as opposed to Fiero part being mounted to the engine cover. Reverse the original orientation of these parts (i.e. the latch hook goes on the decklid, and the piston release goes on the frame)

Install headlights using brackets as supplied and marked in the kit to headlight assemblies. Install headlight covers using any attachment method to the body of Fiero lampholder as per our video. We recommend rivets as they are visually most appealing as well as safe, although difficult to remove if servicing becomes necessary.

Install all lights as per video and mirrors. If power mirrors, use Fiero mirror power mechanisms and reinstall them into new mirror bodies. Install all emblems that need drilling a hole. Do not attach 3M tape backed emblems at this point. [NOTE: I plan to install ALL emblems after painting - protecting the surface for the hole with masking tape, and drilling the holes through the new finish]

Prepare the car for paint. Paint the car. Reinstall all lights and emblems. If the need arises to drill a hole through the painted surface, place masking tape over the hole prior to drilling [:?>]. This insures a burr free clean hole. Look at the video [grrr] several times and follow all safety precautions as recommended by individual tool manufacturers guidelines. If you feel unsure or are not experienced with any or some of the steps described in this manual, contact a professional outfit to do this for you.

6. Soft-Top
Follow the steps as provided with the separate manual with the soft-top kit.

7. Interior
Mount the dashboard to the exact same location from which you removed the Fiero dashboard. You have to reuse the defroster vent cover from the Fiero windshield. Use 2.5 inch automotive round ducts to reroute airflow to the back of the round vents in the dashboard [my dashboard kit has no vent holes]. Seal properly using silicone sealant. Attach doorskins with the same clips removed from the Fiero doorskins. Reuse the handlecover and pull handle / arm support - repainting if necessary with vinyl paint.

Glue carpeting with sprayable contact cement sprayed beneath the underside of the carpet padding.

Using self tapping screws, install the center console prior to installing wiring cover in the middle of the console. All wiring to additional stereo equipment must be finished prior to that. Reinstall seats to original mounting holes [I recovered these first using the PISA leather kit]. Remove steering wheel using steering wheel puller, and reinstall optional steering wheel as per instructions supplied with the wheel.

8. Photos
- this section was directly photocopied from the September 1996 issue of Kit Car Magazine showing the installation of the "Eagle 5" kit from Perry Designs™.