Subject: Crossfire HOW-TO Tech Series Index

Initial Release 07/29/08

Revision 01 08/05/08 – Added REAMED bushing article

© 2008 Steve Simpson – www.theCUBEstudio.com  - steve@thecubestudio.com

IMPORTANT NOTE: These tech articles go thru periodic revisions to add or update info. The link does not change, so check back before you use the instructions to be sure you are using the latest version.

Note: use the browser back button after viewing links in this document.  Adobe .PDF versions of these articles (that can be printed including the pictures) will be available at some time in the future.

Articles released so far:

Crossfire Throttle Body Rebuild including Installation of standard Shaft bushings Difficulty Level: EASY – Special machines required: NONE

http://www.thecubestudio.com/CrossfireThrottleBodyRestoration.htm

A special follow-on article by request is here:

http://www.thecubestudio.com/CrossfireTechFixingFailedAttemptToRepairBrokenOffScrews.htm

Crossfire Throttle Body Rebuild including Installation and REAMING of accurate Shaft bushings Difficulty Level –MEDIUM – Special machines required - Drill press with vice

http://www.thecubestudio.com/CrossfireThrottleBodyRestorationREAMEDBushings.htm

Straightening bent shafts and arms. Difficulty level: EASY – Special machines required: bench Vice.

Above operation IF arms are loose on shafts. Difficulty level: Moderate – Special machines required: Brazing torch.

http://www.thecubestudio.com/CrossfireThrottleBodyStraigteningBentThrottleShaftArms.htm

Building your own water manometer for $6 in materials from any hardware store. Difficulty level: EASY – Special machines required: NONE

http://www.thecubestudio.com/CrossfireHomeBuiltManometer.htm

Correctly and accurately balancing the Throttle bodies. Difficulty level: EASY – Special machines required: Water Manometer, air passage plugs (home made)

Above operation IF balance screw if still welded. Difficulty level: Moderate – Special machines required: Rotary cut-off tool or hacksaw

http://www.thecubestudio.com/CrossfireThrottleBodyBalancing.htm

Follow on articles will cover:

Adding sealed stainless ball bearings to the TB shafts instead of simple bushings. (best) Difficulty level: Advanced – Special machines required – Lathe

Note: After some thought and discussion, I have concluded that this is NOT a do-it-yourself project and this article may not be released. Feel free to comment on that.

Rebuilding the injector POD. Difficulty level: EASY – Special Machines required: NONE

This will be the next article released and the article now contains some optional special performance modifications which will require machining. Standard rebuild is still EASY no special tools.

Porting the crossfire manifold. Difficulty level: Advanced – Special Machines required: Die Grinder (not a Dremel tool), Non-ferrous carbide cutters, Sawzall or rotary cut-off tool, Milling machine. Metal forming skills.

One additional article specific to the 1982 Collector Edition Rear Glass Hatch is here:

http://www.thecubestudio.com/CollectorEditionHatchHingeInstallationInstructions.htm..