VAHokie's Roadster Build Thread - Body Fitment Questions

[VAHokie]

I'm approx. two weeks out from delivery on my MKIV complete kit, so I figured it's time to set-up the build thread, master the art of posting pics, and start documenting all my questions and the forum's great insights. I'll spare everyone the intro and build details as I already documented it here and my signature has most of the pertinent stuff. But I will share a pic from the Build School back in October and the "nursery' pic that Sally @ FFR (who is great BTW!) sent last Thursday (12/13).

[John T]

Welcome to the club. First advice I was given I'll pass on to you. Inventory is really important. Check off everything and that will help you to find it when you need it. Enjoy the journey.

[VAHokie]

Welcome to the club. First advice I was given I'll pass on to you. Inventory is really important. Check off everything and that will help you to find it when you need it. Enjoy the journey.

Thanks for the advice, John. I intend to do a thorough inventory before getting started.

[Cruzzz]

Looks like we will have similar builds although you will have a 6-8 week head start. I should take delivery mid-February. Congratulations and look forward to reading about your build! Will be documenting my build here.

[VAHokie]

Looks like we will have similar builds although you will have a 6-8 week head start. I should take delivery mid-February. Congratulations and look forward to reading about your build! Will be documenting my build here.

Good to know, I'll be sure to follow your build since we'll be on similar tracks. Don't hesitate to reach out.

[phileas_fogg]

Hey Tony,

Regarding the fuel system parts, where they go (and if you'll even use them) will be dictated by your engine choices (EFI vs carb; internal electric vs external electric vs mechanical fuel pump, etc.). I didn't use the nylon fuel line because it was too short to get from the tank to my fuel filter location. I did use the quick connects and the provided rubber hose for my EFI system. In other words, you'll soon have a "Parts Not Used" box, and have to make up the rest as you go.

Regarding the wing nut & fender washer, I don't recall seeing those. But make a note where they're located so if you come up short somewhere you don't have to make a trip to Fastenal.


John

NOTE: If you go with an EFI system, make sure whatever fuel filter you use meets the EFI specification. An EFI system expecting 10u filtration won't last long if all you've got is a 15u filter.

[VAHokie]

Hey Tony,

Regarding the fuel system parts, where they go (and if you'll even use them) will be dictated by your engine choices (EFI vs carb; internal electric vs external electric vs mechanical fuel pump, etc.). I didn't use the nylon fuel line because it was too short to get from the tank to my fuel filter location. I did use the quick connects and the provided rubber hose for my EFI system. In other words, you'll soon have a "Parts Not Used" box, and have to make up the rest as you go.

Regarding the wing nut & fender washer, I don't recall seeing those. But make a note where they're located so if you come up short somewhere you don't have to make a trip to Fastenal.


John

NOTE: If you go with an EFI system, make sure whatever fuel filter you use meets the EFI specification. An EFI system expecting 10u filtration won't last long if all you've got is a 15u filter.

Great info, John, and appreciate the heads-up on the fuel filter specification. I intend to go the carb route and will be sure to confirm that what I have will be sufficient or if I need to swap it out with something else.

[Pat427]

Congrats! I just ordered my kit too. Completion date 2/2/19. I'll be following along your thread. Good luck.

[Cruzzz]

Congrats! I just ordered my kit too. Completion date 2/2/19. I'll be following along your thread. Good luck.

My completion date is also 2/2! Will you be doing a build thread?

[Pat427]

My completion date is also 2/2! Will you be doing a build thread?

Yes, I'll be making a Build Thread. I'm going to wait until I get closer to delivery before I start it up. I'll be on this forum A LOT. Hopefully we can make it through with everyone's help!

[RJD]

Congrats Tony! Here comes the fun. I'm happy for you.

[VAHokie]

Thanks, Rocco!

[phileas_fogg]

Also, when you find your fan, look up the current draw for whatever manufacturer / model you have. Mine was a Maradyne fan that only draws 12-15A. I replaced the 30A fuse in the Ron Francis fuse box with a 20A to better match the expected load. And if you replace the fan's spade connectors with Weatherpak, note that typically the latter are rated to 20A so you'll want a 20A fuse anyway.


John

[VAHokie]

Also, when you find your fan, look up the current draw for whatever manufacturer / model you have. Mine was a Maradyne fan that only draws 12-15A. I replaced the 30A fuse in the Ron Francis fuse box with a 20A to better match the expected load. And if you replace the fan's spade connectors with Weatherpak, note that typically the latter are rated to 20A so you'll want a 20A fuse anyway.


John

Hey, John.

Unpacked the radiator fan and it's a Faz Elektrik M162K-F. Upon googling it, it took me to the Maradyne website and it appears we probably have a similar fan, although mine draws 18a. What advantage does lowering the fuse rating from 30 to 20 to more closely align with the expected load? Wouldn't it be better to have a higher rated fuse to allow for a little wiggle room? Admittedly, the electrical components of the build are where I feel most deficient, so apologize for what may be a noob question.

[VAHokie]

One question for the group and a request for confirmation on two parts. Thanks in advance to all who can share some insight!

First the question: In the Fuel Line components section, it states you should receive two brass barbed fittings, one 1/4" and the other 5/16". Located both (see below), but the one on the left isn't barbed, it's actually a clamp style fitting. Will this be an issue?


Now for the parts confirmation: Can someone confirm these two parts are the LH/RH Pin Mount Plate, Front, 1/16" Steel?


And can you someone confirm these are the 3/16" Steel Door Latch Spacers?

[phileas_fogg]

Hey Tony, are you planning to install a heater? If so, you may find that the 3/4" brace for the dash hoop interferes with the heater body. If so, the easiest solution is to cut out the brace...which means you'll have to rethink your aluminum firewall brace.


John

[Fixit]

One thing with inventory that may help...
There's nut & bolt packs all over the place, in every box, loose with a number on them. During the inventory put the hardware kits in the box of a larger part they go with. I also Sharpie'd the "orphan" hardware bags with the original box number, and combined them in their own box... so now when I move along and there aren't any bolts, I look at my list and find the part # & box number, then go to my new "bolt box" and find the pack.

[VAHokie]

One thing with inventory that may help...
There's nut & bolt packs all over the place, in every box, loose with a number on them. During the inventory put the hardware kits in the box of a larger part they go with. I also Sharpie'd the "orphan" hardware bags with the original box number, and combined them in their own box... so now when I move along and there aren't any bolts, I look at my list and find the part # & box number, then go to my new "bolt box" and find the pack.

Great advice - I'll definitely be borrowing that approach.

[phileas_fogg]

The fuse keeps the wire from melting and potentially causing a fire in the case of current overload. You do need some wiggle room; I believe 10-15% over the anticipated load is the rule of thumb.

In my case, the Weatherpak connectors I used were rated to 20A (you can get higher rated Weatherpaks; you just have to look for them). If I'd left the 30A fuse in place, the actual fuse would have been the connector. Since swapping the spade connectors for Weatherpaks is a common upgrade, and you've got easy access to the fan now, it's an easy decision / change to make.


John

P.S. Yes, you've got door latch spacers. The other brackets must be for the hood pins; I had them left over since I used the gas struts. I don't see the picture of the fuel line fittings.

[VAHokie]

The fuse keeps the wire from melting and potentially causing a fire in the case of current overload. You do need some wiggle room; I believe 10-15% over the anticipated load is the rule of thumb.

In my case, the Weatherpak connectors I used were rated to 20A (you can get higher rated Weatherpaks; you just have to look for them). If I'd left the 30A fuse in place, the actual fuse would have been the connector. Since swapping the spade connectors for Weatherpaks is a common upgrade, and you've got easy access to the fan now, it's an easy decision / change to make.


John

P.S. Yes, you've got door latch spacers. The other brackets must be for the hood pins; I had them left over since I used the gas struts. I don't see the picture of the fuel line fittings.

Thanks, John. Updated the pic above to the fittings.

[BadAsp427]

Hey there. I did not want to steal Yamabro's thread so I'm over here on yours... LOL.... Seriously, on the dolly, I used the same plan that you have except I raised it up by adding a 4 x 6 along with the 4x4.... I used gorilla wood glue and some 7" lag bolts to attach the 4x4 and 4x6 ; It brought the bottom of my chassis up to 21" with the wheels that I got. HERE is my link to my build of the dolly.... I LOVED it as it was very easy to get under and it was up high enough to work without bending over too much. I found it to be extremely sturdy as well. And it rolled around the garage like a dream... Hope this helps. I had some left over red floor epoxy that I coated it with as well... just a nice touch. Hope this helps.
IMG_1213.jpg IMG_1248.jpg

[VAHokie]

Hey there. I did not want to steal Yamabro's thread so I'm over here on yours... LOL.... Seriously, on the dolly, I used the same plan that you have except I raised it up by adding a 4 x 6 along with the 4x4.... I used gorilla wood glue and some 7" lag bolts to attach the 4x4 and 4x6 ; It brought the bottom of my chassis up to 21" with the wheels that I got. HERE is my link to my build of the dolly.... I LOVED it as it was very easy to get under and it was up high enough to work without bending over too much. I found it to be extremely sturdy as well. And it rolled around the garage like a dream... Hope this helps. I had some left over red floor epoxy that I coated it with as well... just a nice touch. Hope this helps.
IMG_1213.jpg IMG_1248.jpg

Thanks, Carl. Dumb question, safe to assume you counter sunk the 7" lag bolts that held the 4x4 and 4x6 pieces together?

[BadAsp427]

Thanks, Carl. Dumb question, safe to assume you counter sunk the 7" lag bolts that held the 4x4 and 4x6 pieces together?

Yup.. just used the appropriate size wood bit (Paddle style) Worked great.... That's also why I ended up with the 4x4 on top.... FYI, pre drill with 3/8" bit and use 7/16" Lag bolts... good catch....

[VAHokie]

Still waiting on delivery but Stewart confirmed it should some time over the weekend. Not to worry though, plenty to keep me busy over the holidays in preparing for its arrival, including building the body buck and chassis dolly. Big thanks to Scottiec for donating his body buck, phileas_fogg for the chassis dolly casters, and BadAsp427 for the chassis dolly enhancement recommendation and confirming some measurements for me. Like so many have commented before, the willingness and generosity of this community are amazing.

For the chassis dolly, I used these plans but added a 4x6 to increase the height and an additional cross brace for some added support. Hopefully the increased height will help spare my back a bit during the build - we'll see.

Here's the body buck and chassis dolly:


And here's an up close of the chassis dolly so you can see the modifications:

[BadAsp427]

For the chassis dolly, I used these plans but added a 4x6 to increase the height and an additional cross brace for some added support. Hopefully the increased height will help spare my back a bit during the build - we'll see.



And here's an up close of the chassis dolly so you can see the modifications:

Looks really nice... great job, it will be a back saver...
Looks very familiar... Nice job... I will tell you that while I was working on my build, I found my self in the engine bay several times while the chassis was up on the dolly. I used the cross support to hold tools, rivets, perhaps a 12oz bev etc several times.... The extra cross brace you installed would have been in my way. And I really do not see where it would have helped me at all. You may find that you want to remove it and you should not have any problems if you do. That is of course if you tied the 4x4 and 4x6 together with a few lag bolts as we discussed.

[RJD]

Looks like you're ready to rock and roll!

[cv2065]

With that design of dolly (same as the one I had), just be careful when you are wheeling the dolly back into the garage once you have the car on it. If you have a lip on the front concrete pad of the garage and you slam the weight of the dolly into it, you can damage your dolly to where it can be unstable. Ask me how I know..

[VAHokie]

With that design of dolly (same as the one I had), just be careful when you are wheeling the dolly back into the garage once you have the car on it. If you have a lip on the front concrete pad of the garage and you slam the weight of the dolly into it, you can damage your dolly to where it can be unstable. Ask me how I know..

Great advice and also the same thing phileas_fogg shared as we wheeled it into the garage and over the small lip I have for mine - I suspect he encountered the same learning experience you did.

[Zuma737]

Thanks again to VAHokie for the invite and to phileas_fogg, Craigs, and jrcuz for all the great info!

[phileas_fogg]

Great advice and also the same thing phileas_fogg shared as we wheeled it into the garage and over the small lip I have for mine - I suspect he encountered the same learning experience you did.

Yup.

Congratulations again, Tony, and thanks for hosting!


John

[phileas_fogg]

As Carl said, you'e got a drive shaft adapter (pay attention to the bolts as you fit it; some have been reported to be a thread or two too long), a right forward floor carpet piece, a pair of spring collars (lots of folks, including myself, don't use the set screws as they goon up the threads), an I-don't-know-what Delrin piece, radiator front aluminum, foot box access cover, and fuse panel mount. The fuse panel mount is for the donor fuse box; the Ron Francis harness comes with its own correctly-shaped panel mount & as I recall is in the RF box with the harness.


John

P.S. Good questions all around. I remember when I did my inventory I had to use process of elimination to figure out what the fuel filter was. Oh how much I've learned!

[VAHokie]

As Carl said, you'e got a drive shaft adapter (pay attention to the bolts as you fit it; some have been reported to be a thread or two too long), a right forward floor carpet piece, a pair of spring collars (lots of folks, including myself, don't use the set screws as they goon up the threads), an I-don't-know-what Delrin piece, radiator front aluminum, foot box access cover, and fuse panel mount. The fuse panel mount is for the donor fuse box; the Ron Francis harness comes with its own correctly-shaped panel mount & as I recall is in the RF box with the harness.


John

P.S. Good questions all around. I remember when I did my inventory I had to use process of elimination to figure out what the fuel filter was. Oh how much I've learned!

Thanks, John. I have to believe the Delrin spring washer goes with the spring collar as that's how it was packed and I encountered the same part packed with the front suspension this evening. What's interesting is that this washer is rubber and the other spring washer I came across in inventory with the steering shaft was metal - I guess they come in different material types.

[JohnK]

Thanks for the build thread. This is all great information! I'm a few weeks behind you. My kit had a 12/22 complete date, so as Sally says, my "baby is in the nursery" waiting for Stewart to pick it up. Per my last discussion with Stewart, it should be picked up late this week or early next week and then it will start its long journey to the west coast. I'll be keeping tabs on your progress. Good luck!

[VAHokie]

Thanks for the build thread. This is all great information! I'm a few weeks behind you. My kit had a 12/22 complete date, so as Sally says, my "baby is in the nursery" waiting for Stewart to pick it up. Per my last discussion with Stewart, it should be picked up late this week or early next week and then it will start its long journey to the west coast. I'll be keeping tabs on your progress. Good luck!

Glad this info helps! If you haven't already, ask Sally to send a nursery pic to add to your photo library. There's something about seeing your name, on your car that makes it feel real - at least it did for me.

[JohnK]

Glad this info helps! If you haven't already, ask Sally to send a nursery pic to add to your photo library. There's something about seeing your name, on your car that makes it feel real - at least it did for me.

Already done!

IMG_1632.JPG

[VAHokie]

I continue to work through inventory, averaging 1-2 hours a night. My hope is to be done by the end of the weekend, which will be a week after delivery and consistent with what others have shared it took them to complete it. I'll be able to start the actual build, or should I say tear down process? I tackled the Fuel Tank and eBrake boxes last night (as well as a few others) and wanted to run a few things by the group:

I believe these are the 3/8-5/16" and 1/4" fuel line connectors, but would like to confirm. It's not entirely clear in the instructions where these go, but in reviewing the pics in the manual it appears they attach to either end of the fuel filter - does that sound right?


I also have two hoses, one is clearly the nylon fuel line that connects the filter with the tank (Part Name: Tank to Filter Fuel Line Assembly), and the other is Part Name: 1/4" ID, High Pressure Flexible Fuel Line. Can someone confirm where this goes?


In the eBrake parts, I had two leftover items that weren't on the actual parts list: a wing nut and washer. Did anyone else receive these?

[phileas_fogg]

Well well well...I was beginning to wonder if you'd abandoned this thread!

Good to know you're making progress.


John

[VAHokie]

Well well well...I was beginning to wonder if you'd abandoned this thread!

Good to know you're making progress.

John

Slow,progress, but its progress!

[jrcuz]

Hi Tony, I just thought that when you get your engine and trans you will need to dial indicate your bell housing. It is very easy to do with the proper tools. When I got my eng/trans from Mike Forte I confirmed with him he doesn't do this. There are several videos on youtube, check out american powertrain for their video. As they say if you don't do this step and you have trans bearing problems down the road your trans is not covered under tremec's warranty. I have the dial gauge to do it with or you may be able to get one on loan from an auto parts store. I bought mine and a magnetic base from Harbor Freight for cheap money.
Good progress on your inventory.
Jerry

[VAHokie]

Hi Tony, I just thought that when you get your engine and trans you will need to dial indicate your bell housing. It is very easy to do with the proper tools. When I got my eng/trans from Mike Forte I confirmed with him he doesn't do this. There are several videos on youtube, check out american powertrain for their video. As they say if you don't do this step and you have trans bearing problems down the road your trans is not covered under tremec's warranty. I have the dial gauge to do it with or you may be able to get one on loan from an auto parts store. I bought mine and a magnetic base from Harbor Freight for cheap money.
Good progress on your inventory.
Jerry

Hey, Jerry. I appreciate the reminder on this. I recall you mentioning that during my visit to see your build and actually have it noted in my discussion notes. Still a bit out from this step, but I'll be sure to connect when the time comes.