JAVELIN SPORTS CARS Ltd - Cabrio Info Pack

The Cabrio Kit was originally designed by the acclaimed Paul Moorhouse to incorporate the maximum number of components from the robust and reliable Ford Sierra, making it a truly one donor vehicle.

Introduced in 1982 the Sierra was produced in a variety of forms from the humble 1.3L to the mighty race and rally winning Cosworth. The Cabrio design brief was to produce a vehicle with handling and roadholding, worthy of comparison to one of Germanys principle sports car manufacturers products, and capable of being fitted with the powerful Rover V8 family of engines. Yet also incorporate several unique safety features, some of which are not yet seen in mass produced production cars.

A Mk2, LWB car was subsequently produced and now Javelin, in cooperation with Marlin, have introduced the Mk3 Cabrio using BMW 3-Series for the donor parts.

The real strength of the Cabrio is in the steel fabricated and welded, semi-monoque platform chassis, which has exceptional torsional stiffness. Onto this masterpiece, all of the other components are directly attached, resulting in a construction, that is free from shakes and rattles, whilst also providing the car with a smooth and supple ride.

This Build Manual is intended to be used in conjunction with a Haynes Workshop Manual, these are generally so comprehensive that no attempt has been made to duplicate their information. We strongly recommend the purchase of a Workshop Manual as early as possible. In it will be found information to help you choose exactly the donor model best for you. For example, gear ratios, brake sizes and spring rates vary from model to model.

The Javelin 'Basic' kit' is offered in three comfortably sized packages and are, in fact, very comprehensive. On collection you will find that there are many items included along with the chassis and basic body panels.

Many customers choose to purchase their kit in stages, you can also buy everything else you may need the same way.

Think of the space you may need - for your donor car, the kit and room to build! - Buying in stages means that you do not have to store or pay for any parts until you are ready to use them. Optional extras are available, these tend to include items that you may wish to make yourself, purchase locally, or which require you to make a choice of colour/ material etc.

To ensure you are supplied with a complete kit you will be asked to check all parts against a list supplied at the time of collection or delivery.

Javelin Sports Cars Ltd are confident that you will be able to build a Javelin Cabrio kit using this Build Manual. However even the best of us may wish for a second opinion and we are happy to discuss any detail of the build with you, contact us on our usual number 01274-619608 (UK).

Contacting the Marlin Owners Club is also possible, where you can talk to owners that have already completed a kit or those that are building right now.

No specialist tools are required to build your Javelin kit. The sort of tools required are:-

No one wants an accident, but unfortunately they can happen. Cabrio kits have an excellent reputation for occupant protection and robustness of the cars in an accident.

Replacement parts for all areas of the car can be supplied, from a front wing, to major chassis repairs.

Due to their infrequent and varied nature no price list exists for replacement parts, but in most instances we are able to quote within a few days.

Personal safety is an aspect of kit car building often overlooked. No matter how keen you are to get on with the job, observing basic rules can avoid an accident save time and money as well as expensive mistakes.

It is recommend that you read the 'Safety First' section found near the front of Haynes Workshop Manuals.

In order to build your Javelin Cabrio kit you will need all the mechanical components detailed in Section 1.8.3 from one of the above vehicles.

The best way to acquire most of the mechanical parts is to buy a complete car that is either rusty or crash damaged but mechanically sound. Contact local motor salvage dealers ('Car and commercial Vehicles breakers' in the Yellow Pages), look in the auto press or place a wanted advertisement in your local newspaper.

Javelin are always pleased to discuss requirements of what combination will be most suitable.

Javelin recognise the difficulties encountered when dismantling donor vehicles. Regulations in force and future proposals will almost certainly preclude this as an option. Accordingly we operate a palletised donor package system, backed up by a complete range of reconditioning parts and service items.

Differential unit with mounting bolts.
Trailing arms complete with drive shafts.
Springs, dampers, rubber bump stops and spring seats.
Pivot arm bolts (4 off).
Retain 4 prop-shaft to diff flange H.T. (High Tensile) bolts.
Brake assemblies and hubs.

Retain all fasteners, etc. The rear anti-roll bar is not used in the Cabrio and can be dispensed with. Consider replacing springs, dampers and brake pads.

Generally lower powered cars should use higher axle ratios, and higher powered cars should use lower axle ratios. The differential from your donor should be suitable.

Brake assemblies and hubs (consider replacing pads). All other parts are supplied by Javelin.

Steering column complete, including all switch gear and cover mouldings. Also retain the steering link shaft.

N.B:
(1) Power steering will not fit the Cabrio chassis due to the bulk of the valve body.

(2) The bespoke wiring loom is designed to fit the BMW switchgear (See finishing touches).

Master cylinder assembly including reservoir. 3 way union for rear brake pipes. Brake light switch. Handbrake lever and cable.

The bespoke pedal box, included in the kit, is designed for the hydraulic clutch and brake.

Engine and gearbox with all attached components including air filter, alternator, starter and fan. Coil, fuel bypass regulator, ignition black box, the radiator hoses and header tank. Keep the Engine Control Unit (ECU) and engine harness fuel pump and filters.

Heater and fan parts are available as a kit from Javelin. The BMW unit includes air con and is too large.

A serviceable system can be made by shortening the original BMW exhaust. Alternatively our stainless systems will complete the job for you in one go and can fit onto the standard down pipe.

The engine loom & ECU wiring must be retained which can be used along side the Javelin Cabrio loom. This loom is relatively simple and contains the majority of plugs, grommets, fuses and relays that you require. (See finishing touches). Due to the variety of different components and modifications the BMW has experienced, it would be wise to retain all of the plugs and connectors, for each piece of electrical equipment you wish to re-use in building your Cabrio, to avoid frustration later on.

To use our standard aluminium dash retain rear fog lamp switch, fog lamp switch. , rear door electric switches and foot well lamps. Also remove from the fuse box all fuses and relays.

NB: The BMW instrument pack can be set in the centre of the facia, but you will need to make a special dash.

Development to use the BMW door furniture is ongoing. Retain as much as possible. Alternatively, you can use Sierra parts which you can source yourself, or we can supply as a kit.

Rear view interior mirror, horn, wheels/tyres, seatbelts, steering wheel, stereo, battery and clamp, may all be useable.

N.B: The Javelin nut & bolt set included in the kit contains most of the fasteners required to assemble a standard specification Cabrio unless otherwise stated.

It is however, advisable to purchase a selection of new metric nuts & bolts. In practice this will save hours of searching for misplaced fasteners and also enhance the appearance of your finished Cabrio.

Differential unit with mounting bolts and large rubber V shaped mounting.
Trailing arms complete with drive shafts.
Springs, dampers, rubber bump stops and spring seats.
Pivot arm bolts (4 off).
Retain 4 prop-shaft to diff flange H.T. (High Tensile) bolts.

If purchasing separately, this complete assembly is contained in a fabricated steel tubular "horseshoe". The components can be taken out, and this item becomes redundant. Retain all fasteners, etc. Certain Sierra variants have a rear anti-roll bar incorporated in this unit; this is not used in the Cabrio and can be dispensed with.

The Sierra disc brake rear axle 1990 onwards 2L and above, Granada (1985 on) family and Cosworth applications can all be fitted into the Cabrio chassis for the ultimate performance options.

Reference is made to the full range of ratios available in the relevant section of the Haynes manual.

Generally, 4 cylinder powered Cabrio's with 5 speed transmissions, work best with the 3.92:1 ratio to allow for the additional rolling radii of the 15" tyres.

V8 and higher output motors and non overdrive automatic transmissions should be the 3.62:1 or 3.38:1.

Complete track control arm and anti-roll bar assembly including anti-roll bar rubbers and clamps and all bolts and rubbers. Steering rack and steering arm ends. Front suspension uprights and brake assemblies, but NOT the Macpherson struts.

Steering column complete, including all switch gear and cover mouldings. Also retain the lower column shaft.

N.B:
(1) Power steering will not fit the Cabrio chassis due to the bulk of the valve body.

(2) The bespoke wiring loom is designed to fit the MK11 (post '87) Sierra switchgear (See finishing touches).

(3) Late Sierras incorporated an adjustable steering column. Enterprising builders may wish to fit this to their vehicle which can be done with some thought and minor modifications to the hanging arrangement.

Brake servo and master cylinder assembly including reservoir. 3 way union for rear brake pipes. Brake and clutch pedal assembly with the pressed steel bracket to which they are fitted, all clips, washers, pins etc. Brake light switch. Handbrake lever and cable.

Engine and gearbox with all attached components including air filter, alternator and fan. Coil, fuel bypass regulator, ignition black box, and the radiator hoses. Standard clutch cable and accelerator cable and pedal. In the case of injection engines keep the Engine Control Unit (ECU) and engine harness fuel pump and filters.

NB: If the engine and gearbox assembly requires a hydraulic clutch we would need to know, so that the chassis can be built to suit. (Eg. When using a Rover V8 engine and box.)

However, you may wish to disconnect the sliding joint at the rubber coupling to remain inside the Ford type 9 (5 speed) Sierra gearbox to seal the tailshaft, but retain also the 4 special HT propshaft to differential flange bolts.

Heater unit and mounting washer, fan unit, demister flexible ducts, bulkhead heater pipe sealing plate, dashboard control unit and cables.

The Sierra radiator will not be required for the Cabrio (see section 3.2 new manual).
2.3, V6 engines can use a modified 2.3 Sierra bottom hose; 2.8L, V6 engines use V6 modified Sierra hoses.

Wiper subframe, washers and nuts complete with motor. Washer bottle and hoses (optional).

A serviceable system can be made by shortening the original Sierra exhaust. Alternatively our stainless systems will complete the job for you in one go and can fit onto the standard down pipe.

The Sierra looms vary in complexity to accommodate an increasing variety of sensor units, ABS etc.

The engine loom & ECU wiring must be retained which can be used along side the Marlin Cabrio loom. This loom is relatively simple and contains the majority of plugs, grommets, fuses and relays that you require. (See finishing touches). Due to the variety of different components and modifications the Sierra has experienced, it would be wise to retain all of the plugs and connectors, for each piece of electrical equipment you wish to re-use in building your Cabrio, to avoid frustration later on.

To use our standard aluminium dash retain rear fog lamp switch, fog lamp switch. , rear door electric switches and foot well lamps. Also remove from the fuse box all fuses and relays.

NB: The Sierra instrument pack can be set in the centre of the facia, but you will need to make a special dash.

Remove the latch unit with screws and wire links to interior handles, exterior handle and screws, keylock, plastic bezel and interior clip. You also need electrical loom and rubber trunk, courtesy light switch and window winder mechanism.

Don't forget the channel at the bottom of the door glass (you will have to smash the glass to get it off). Keep bolt type striker pin with fixings and backing plate and door seal. If you have a later car with a loop striker you will need to obtain a pair of early bolt type strikers as above, these work well with later type locks.

N.B: The Javelin nut & bolt set included in the kit contains most of the fasteners required to assemble a standard specification Cabrio unless otherwise stated.

In order to use the Rover manual gearbox, Javelin will need to supply a hydraulic clutch chassis.
Engine & gearbox, manual or automatic and standard Rover mounting rubbers, or you can use a special Javelin type - please specify when ordering kit. The chassis is designed to accept the SDI type two bolt mountings.

The option of cotton reel types now exists - built to order only. Make sure you have all of the ancillaries, including the ignition ballast resistor and in the case of injection engines, all of the engine wiring loom and engine control units.

N.B: Manual and automatic versions of the SDI propshafts, have different hole spacing & lengths. Specify type & length when ordering.

BMW 320, 323, 325 straight 6cylinder engine & gearbox (Option for Mk2)
(Most 4cyl BMW engine & gearboxes can also be used).

In order to use BMW 4 cylinder/small block 6 cylinder engines, Javelin will need to supply a hydraulic clutch chassis. You will need to take from the BMW, the entire engine and gearbox assembly (manual or automatic) and all items needed to run and control it, plus the first stage of the exhaust system.

Many varied engine options can be used, such as BMW 2.0 (4 & 6 cyl.), 2.3 and 2.5 (6 cyl.), or even the Volvo 2.5, but always use the corresponding gearbox.

Inspect all donor parts and check that they are in good condition. Worn parts should be re-furbished to ensure safety and reliability.

Where appropriate, apply paint or another corrosion inhibiting coating to refurbished parts, for both appearance and durability. There are several well-known paint systems on the market, and the manufacturers give full and easy to follow instructions on their application.

There are some items required which do not come from the donor car and are not supplied in the basic kit. These are listed below. We do not stock items which are readily available locally, unless we can offer a competitive price. Other items are available from us, but you may have a personal preference, or alternative source of supply.

We can supply new propshafts for Mk2 and Mk3 cars to suit individual requirements, including conversion of the Ford MT75 "GAF" type coupling to universal joint.

To make up your own we can supply a short splined extension shaft and universal joint (See finishing touches), or alternatively we can supply a new one piece shaft manufactured to OE specifications.

Three point inertia reel belts with 300mm long stalks, e.g. Securon 500/30 (available from us).

Either - Special shortened Sierra or BMW cable from Javelin. Or - the original Sierra or BMW cable can be shortened and then a new ferrule fitted to one end by yourself following the instructions as in section 2.2.

Depending on the power unit Javelin can supply three radiators to suit a large variety of applications (see finishing touches and section 3.2).

Adjustable wiper arms, set length to 330mm from centre of blade to centre of spindle (see section 7.3). The Sierra and BMW spindles have a 10mm DIM fitting and M8 nuts. Wiper blade 11 inch.

A special long range 12.5 gal (60 lt.) alloy fuel tank is required (specify Ford or BMW), also 50mm fuel filler hose and 2 x 55-75mm hose clips. Sierra Sapphire filler neck, vent tube & cap can be used.

2.4 metre (per line) of 8 mm OD. copper hard lines, with high-pressure flexible connector pipe, "P" clips, fasteners, etc.

This will depend upon the power unit fitted (usually found mounted in front of the axle line below the boot floor).

Four SVA type or two bonnet deadlocks (requires fixed side panel kit specify when ordering).

Main beam, ignition, oil, indicators, brake level and a GM Vauxhall 3 position rotary switch for the heater.

Headlights
Stainless steel headlamp bar
Rear fog lamp and reversing lamp or 2 rear fog lamps.
Rear number plate lamps x 2.
Front indicator lamps - motor cycle units are ideal.
Suitable connectors for lights

20 pipe clips for brake pipes - 3/16" OD tube (5mm).
10 pipe clips for fuel piping - 5/16" OD tube (8mm).

Suitable for wheel widths; speed and rating depends on the power unit fitted, and the type of use to which the car will be put. From 195/65 x 15 to 215/60 x 15.

N.B Tyre size will effect overall gear ratios and speedo calibration is required.

For screen glass, e.g. Sikaflex 221 or Bostick Autoseal 130 FC adhesive sealant can be used for panel sealing, but subsequent dismantling is difficult.

Javelin recognizes the difficulties encountered when dismantling donor vehicles so we operate a palletized donor package system. If you do not fancy the search, transportation, storage, dismantling & final clearance of your donor car � let us do it for you. We will have the car inspected by the local DVLA, steam clean the parts and put them on to a pallet ready for your collection and re-conditioning. The cost is dictated by your choice of donor but normally will be between �400 & �600 approx.

We can also supply you with everything that you need to build your kit. All these parts come as packages and are a complete range of reconditioned parts and service items. Indeed with these on offer it is feasible to construct virtually a 'NEW' car. Please contact the office for a complete package price list.

To finish a Cabrio to a standard you can be proud of you will need to allow between 7k & 10k. Do remember though, this is largely dependent on how much you pay for a donor and also whether you

paint & trim the car yourself. You will also find that any Cabrio�s that come on the market do so at

good re-sale values, unlike a lot of other kits. You will also notice that they come up for sale very

rarely due to the builder enjoying the car & not being disappointed with the end result.

ONCE FINISHED YOU WILL END UP WITH A CAR THAT WILL RETAIN IT'S GOOD LOOKS AND VALUE!!

PERFORMANCE	0-60 MPH in approx. 5.0 secs. (dependant on engine fitted)
DONOR CAR	BMW 3-Series (E30 model)
DRIVETRAIN	BMW 2.0, 2.3, 2.5 ltr OHC straight six.
WHEEL & TYRE FITMENT	From 195/65 x 15 to 215/60 x15 on 6�" or 7" wide rims.
SUSPENSION	Double wishbone, utilising upright stub axles, coil-over shock absorbers. Rack and pinion steering. Semi-trailing arm rear suspension with chassis mounted differential.
BRAKING SYSTEM	Servo assisted split front/rear ventilated disks front & rear.
DIMENSIONS	Height Length Track	4' / 1.22m 12' 9" / 3.88m 4' 8" / 1.42m	Width Wheelbase Weight	5' 6" / 1.66m 8' 10" / 2.69m 16cwt / 850kg

Please allow up to 28 working days for delivery. Some trim items may take longer.

Since Marlins were first produced in 1979, over 2000 kits have been manufactured and sold.

Due to our policy of continuous development, prices & specifications are liable to change without prior notice.