BROADCAST (aka BUILD) SHEETS

According to John Hinckley, GMAD-Lordstown Vega Launch Coordinator, in the 1st Quarter 2002 issue of the Cosworth Vega Magazine, even the broadcast sheet was different for the Cosworth Vega.

He wrote that, 

"The normal Chevrolet broadcast sheet (which many people refer to today as the "build sheet") was an 8-1/2" x 11" printed form, with many boxes for part numbers and/or broadcast codes for both Body Trim and Chassis operations. When I began to develop the Vega Broadcast sheet long before production started, it became obvious that we couldn't use the standard Chevrolet sheet, as they were printed in about 30 locations throughout the plant on teletype printers (the ones that use the little hammer striking characters on a laterally-shuttling carriage), and it wasn't possible for the teletype printers to print the standard-length broadcast sheet at 106 [cars] per hour. About 80 per hour was the best they could do (none of the other plants had ever run at more than 65 per hour). There was no help in the wings from the printer manufacturer, so I arbitrarily cut the length of the sheet in half, condensed the codes, and created a Body Broadcast for Trim and Final operations and a Chassis Broadcast for Chassis and Engine Line operations; this was the only way the printers could keep up with production. That's why the front end of a Vega on the Final Line looks like it's "papered" with sheets--it took twice as many Broadcast sheets per car as at any other plant (and about 600 of them per hour filled up the trash cans in a hurry at the end of the line!)"

Where can I find one?

What does one look like?

What does it tell me about my Cosworth?

The subject of Broadcast/Build sheets once created quite a discussion on the Yahoo! message board over a period of several weeks. Enjoy this edited version of those postings.

Ok, what's the usual place to find a build sheet?  I'll look for mine there!

We now know that there was no specific plant policy on what to do with broadcast sheets.  The primary sheet for each sequence number going down the line was taped to the top of the radiator support and was usually removed by an inspector toward the end of the line.  Broadcast sheets on subassemblies from other departments were used by the installer to verify that the subassembly was going on the correct sequence number and then they were usually thrown in the trash can or on the floor.  At up to 106 cars an hour, there was a lot of paper.  About the only explanation for the ones that we find is that some assembly workers just found it more convenient to place the sheet, for example, behind the seatback rear trim cover rather than throwing it in the trash or making a bigger mess on the floor.  Perhaps those at the base of the radiator was one worker's way of getting rid of it.  As far as the folded up sheet in the lateral reinforcement between the upper shock mounts, all I can figure is that in a slack moment a worker just folded it up and stuck it in the hole, but who knows, maybe he knew that some restorer would want it 25 years later.  Like I said, there was no plant policy on what to do with them, other than throwing them in the trash or sweeping them off the floor for the same fate.  All we can say to those guys who wadded them up or otherwise stuck them into some cranny is thanks a lot, wherever you are.  Doctorduke 1593

Lemme guess.  Under the carpet in the left rear passenger seat footwell.  doctorduke

No, in the back panel of the passenger seat.  I checked the well already.  That’s why I thought it was long gone.

Ah hah!  You're the second person to tell me this recently.  I found a broadcast sheet under the carpet in the right rear foot wheel about 15 years ago, but it was half disintegrated, so I plan on removing the back cover of the passenger seat to see if I might find another one there.  The only thing that puzzles me is why one would be there.  The sheet taped on the floorboard was visible as the cars went down the line so the guys could see what parts to put one.  Why they stuffed one into the seat is a mystery to me.  I don't think it was to help restorer's 25 years later.  Anybody have any ideas on this one?  doctorduke

Try behind the front passenger seat back.  We have found 6 there.  Even some from a ‘75 CV.  Tim

 After reading the build sheet post's I rushed out to the garage to pull the backs off of my seats.  Alas!  Behind my passenger seat back was a 99% BUILD SHEET!  (Only a small tear in the center)  A very white and readable copy, unlike my browned original, was found under the right rear seat.  Just thought I’d let you know.  Craig.

 I just checked behind both front seat rear trim panels - no build sheet for #2110, and we figure my car was probably built two shifts after Craig’s.  Craig now has two readable build sheets, and I just have the half sheet I salvaged off the rear seat foot well fifteen years ago.  Oh, well!  doctorduke

 Duke, try behind the driver's seat.  I hear that was another spot.  I found mine behind passenger seat on 1105.  I haven’t checked other cars yet.  Art

 I think Bob Chin found a build sheet for his Blue CV rolled up in the radiator core support.  Tim

According to Paul Wicker several build sheets were attached to the car.  Why behind the seat, Paul may know.  Tim

 Duke, the CV was built in an era before Johnson Controls, Lear Seating, and Delphi Seating Systems and their associated "just in time" seating delivery systems.  The seat covers were sewn at a Fisher Body "cut and sew"" plant (Livonia, MI, Grand Rapids, MI were two location I know of) then were shipped to the plant where they met up with foam and frames in the "Seat Build Area".  So as each vehicle was scheduled from the Body Shop, a copy of the "Broadcast" (“Build” to us) sheet was printed in numerous locations.  One of these locations would have been "seat build" where the proper type of frame, foam, and cover would have been selected and the seat built.  They were then placed as a unit to be shipped to the General Assembly (GA) area where they would be installed in the car.  A broadcast sheet inside the seat back?  Likely, the seat back was the last component installed, so rather than pull it out they just covered it up.  As far as the number of "Broadcast sheets", one of the general foreman in GA told me up to 7 were hung with masking tape in different places.  I have a photo of a black 77 GT going down the line at Lordstown with the hood open and a sheet taped just above the grille.  According to my source, it informed the installers which bumper (Rub strip or not) to install.  Hope this helps.  Paul

Sunday night perusing messages I saw members recovering build sheets.  Of course I ran to garage, began removing passenger side rear panel on my ‘76 10k car with original tires and spare never on ground.  To my surprise I found a perfect build sheet.  It was like winning the lottery.  Thanks for the info.

By the way, thanks for the 411 on the build sheet locations.  I have had my radiator out before and no build sheet, so I guess it's back to the garage with my switchblade! (only kidding)  Craig.  P/S.  When you pull the back of the seat off and find a clean build sheet, it is like hitting the lottery. 

There is one other place that I have found a build sheet.  One time I pulled a passenger seat out of a car and there was a build sheet on the bottom of the seat between the foam and the springs.  Chris

Those of you that can’t find your build-sheet, you might drop your gas tank down, and find one on top.  I found one there before.  I'm sure a lot of tanks have been dropped already.

 I found a build sheet folded, rolled up, and stuffed in the right rear frame rail.  Took almost an hour to recover it intact.  I was working on the fuel tank and spotted the build sheet through one of the holes in the rear cross member between the fuel tank and the bumper.  I did not have to remove the tank.  I happened to notice the sheet through an oval shaped opening in the cross member.  My thought: Looking at the build sheet and the 1976 Vega brochure options listing, I surmise each optional item or sub-assembly arrived at the assembly line as the chassis did.  A copy of the build sheet would arrive with the part or assembly to insure the correct part was installed on the right car.  Rather than finding a trashcan for the sheet, the assembly line worker could have stashed the sheet in any available place or opening.  For example, the Cosworth had a special fuel pump not installed in other Vegas.  It also had an optional bumper assembly not installed on stock Vegas.  Both would have been installed from the pit beneath the line.  However, the high-pressure pump may have been installed at the end of the line where the Cosworth specific components were installed.  This could be why they are found in so many places.  Mike Dwyer

I found the build sheet for 1975 CV#0126 underneath the carpet near the center hump under the rear seat.  dkamemes

 

Inside the doors and up under the dash are other places they sometimes show up on other GM cars, but under the carpet on a Lordstown car is your best bet.  If you remove the door sill trim plates you should be able to lift the carpet enough to see or slide your hand into the rear footwell area, which is where it should be.  There were very few options on CVs so you can probably duplicate the sticker by inspecting the equipment on the car.  BTW, the repro stickers look okay to casual inspection, but if you compare them side to side with a real one, there are a lot of small detail differences.  Duke

Can anyone tell me where to look for build sheets in the 75 cars?  Looked behind the seat backs and under the bottom ( between the foam and springs ) and above the gas tank ( had a fuel leak ) and have found nothing yet.  Haven't pulled up the carpet yet, but was hoping for another location.  Would really like to find a build sheet so that I can get a repro window sticker made.  Number 0009 is slowly waking up from a 5-6 year sleep!  And it has only taken me a week's work!  Thanks in advance, Don

I was up in the loft of my "barn" and decided to check out my three saved passenger seatbacks.  I found two build sheets.  One was complete, while the other had the upper left corner missing.  I checked Ken's #2584, and my green # 3387, and found nothing.  Two more cars to check another day.  The options on the two sheets I found were almost but not quite identical.

 

1-V77E-5U 244536 was built for Clark Maple Chevrolet Company, 1036 N. Clark St., Chicago, IL 60610.  The schedule month and date info is 58-89’76 and 06-26.  I'll call this # 1.

 

1 V77O 6U 179168 does not have the build date--it was torn off.  It was sold to Lally-Fiedler Chevrolet, Inc., 500 Broadway, Box 308, Bedford, OH 44146 (a suburb of Cleveland).  I'll call this #2.

 

#2 lists A44 ADJ PASS SEAT and BS2 ACOUSTIC PAKG and UA1 H/D BATTERY. #1 does not list them. Further, #1 lists D90 SPORT STRIPE, while #2 lists 52A GOLD STRIPE, although both are clearly Cosworths as they have the LY3 TWIN CAM ENG.

 

The only other significant difference I could see was the indication on #1 of XXX CUSTOMER ORDER at the right margin.  Does this mean that it was used in those kinds of movies, or is this merely a description of the customer?

 

Mark.  If you research some of the production figure data in a past (way past, try '85) issue of the CVM you will find a reference to order types.  I believe (from memory) there were rush orders, sold orders, and stock orders.  The customer order identification (both then and now) is a priority in the build scheduling at the plant.  Therefore the indication on the broadcast sheet was consistent in communicating this to the entire build team.  It seems logical that the ‘75 would be a sold order as there was an order backlog and high interest in the car early in the introduction period.  It is doubtful that the ‘76 was a sold order.  Paul

 

It reads: Z09 TWIN CAM ENGINE".  Below this are the paint and interior codes. 19W means black vinyl seats.  The acoustic package was standard on the CV.  The other items are options, but options on a Cosworth don't mean much.  With the exception of the five-speed and positraction, all other options were minor "comfort and convenience" features.  The value of an individual car comes down to its condition and documentation.  All this info comes from the TCT portfolio.  You should buy it from CVOA.  doctorduke

 

The Cosworth Vega was a separate and distinct model within the Vega line, rather than an "option" to a Vega hatchback coupe.  The major features such as the engine were included in the sticker (at no charge) for information on the major features of this model.  The repro stickers are not very accurate and the errors and omissions are obvious when compared to a genuine original.  You didn't list one "no charge" feature - "LY3 122-EFI TWIN CAM L4".  This is on all ‘76 original stickers.  Doctorduke

 Chris, Covrace and I found 2307's build sheet in the usual spot today and were extremely surprised to find out that it was originally a 5-speed, 4:10 posi with a lot of options car.  I will Xerox the sheet and mail you and Steve Larson copies.  Only a slight problem is that it was in two pieces when we found it so some of the info is unreadable ( just a tiny bit).  The sheet matches a lot of the other info that I got with the car.  It was originally sold in Orange, CA and was built on 1-8-’76.  It has a black exterior with a black cloth interior.  I hope this little bit of info helps with the prior discussion about colored Cosworths.  Bob.

Thanks guys for letting us know about the build sheet location.  I looked on the back of the passenger side bucket seat on my ‘76 Vega GT and there was the sheet.  Turns out the car was delivered to a local Chevy dealer when new.  Confirmed a lot of things as original for me.  George, Seattle

Was wondering if anyone knows if GM reproduces build sheets.  Like they do for Pontiac.  John  Cosworth1123

 

No.  To the best of my knowledge the only vintage Chevrolet build sheets you can still get are Corvettes built at Bowling Green from '82 on.  Chevrolet has a different administrative system than Pontiac.  Chevrolet builds a lot more cars and they seem to be in the habit of disposing of production records, whereas Pontiac retained them.  Duke

 

No way to get build sheet for any car that I know of.  On USA sold Cosworth Vegas you cannot get any original papers or copies of these papers from GM.  Canada sold cars have the invoice or something similar on file; I don't know exactly what they have.  GM probably has this information on microfilm (like Pontiac) but dosen't care to offer it to public.  I have done title history for a few cars to get ownership history.  I actually talked to ex-owners of my cars.  This can get you back to original dealership's name.  I found the second build sheet on my car in the early 90's.  Possibly there is still more in it.  I haven't looked in all the places.  Maybe your car still has one.  I have many records of cars, but nothing from GM.  I store EVERYTHING an owner provides me on his car, except their address or information they don't wish to share.  If you tell me a PO's (previous owner's) last name, I can search for it.  Well, almost (some of my data from the early 80's needs to be bumped up to MS Excel).  This comes in handy when a dash number isn't provided.  So, send me what you can!  steve larson

 

"GM probably has this information on microfilm (like Pontiac) but dosen't care to offer it to public."  Very unlikely, Steve.  About ten years ago, a staff engineer working directly for Jim Perkins searched high and low for Corvette production records from St. Louis and came up empty handed.  He has reported this to the National Corvette Restorers' Society.  Chevrolet's administrative systems were different than Pontiac's, but they both had to comply with corporate guidelines including legal staff review.  If Chevrolet had the records, like Pontiac, they would release them.  I doubt if the situation at Lordstown was any different than St. Louis except for the fact that Lordstown probably generated ten times as much paper work.  GM and Chevrolet aren't holding out.  Those old production and engineering records were disposed of a long time ago.  Duke