Originator: Stephen I. Dains/sdains
Page 17 of 29
Date Issued: 2-16-04
guidebookcommon spring 2004.doc
DateRevised: 5/27/2004
E0804
Note that any exhaust systemmodificationsmay require recertification toapplicableemissions
andnoise standards
E0900
FRAME
E0901
Welding, cutting, or drillingof theOEM frame rail flanges is unacceptable, except as allowed
withineachuniqueprogram's guidelines. Also see IndustryUniqueSection. Note that the
frame rail flange includes thebend radius area (i.e., approximately¾ inch from the flange).
E0902
Always disconnect thebatteries and sensitiveelectronic components beforeweldingon the
frame. These sensitive components include thePowertrainControl Module (PCM), andother
sensitivemodules addedby thebuilder. (SameasE1114)
E0903
Theadditionof front towhooks is not recommended. If added, C/FMVSS recertificationmay be
requiredon vehicles of 10,000 lbGVWRor less. Towhooks arenot tobe locatedacross the
frame convolutes.
E1000
BODYANDSEATING
–Alsosee IndustryUniqueSection
E1001
FORDBODY
Modifications of theOEM roof bows, roof panels, andbody sidepanelsmay affect C/FMVSS
208, 212, 214, 219, and301 compliance. All OEMbodymodificationsmust be consistent with
the
IncompleteVehicleManual
or verified for compliancewithCanadian/UnitedStatesFederal
Motor VehicleSafetyStandards.
Any deviations from the
IncompleteVehicleManual
must be supportedby engineering
analysis, development prove-out, or testing to demonstrateequivalency to theOEMbody design
and compliancewith theaffected standards.
E1002
Protect all body panel drilledor punchedholes or cutouts from corrosionwithaproduct
containing zinc-phosphateor barium-sulfateas theactive ingredient. Zinc coatingmaterials
should containaminimumof 92percent zinc. Twopart epoxy coatings arealsoeffective.
E1003
Controls, components, or panelsmust not bemounted inpotential occupant impact protection
zones; refer to the
IncompleteVehicleManual
for definitionof these zones on theE-Series
and consider similar areas on theF-Series. See theappropriate IndustryUnique section for
additional instructions.
E1004
Protect the fuel system components fromdamageduring thebuild. Use floor templates to
identify areas of the floor tobeavoided toprotect the fuel systemandusedrill stopswhen
drilling through floor or frame side rail web. Drillingof frame flange is not allowed
E1005
Verify that nobolts or screws arepointed toward the fuel tanks or lines. Any fastener projections
in closeproximity shouldbe shielded toprecludepenetration ina crash. Attempt to locate
fastener protrusionswithinbody sills and frame crossmembers.
