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Thread: VAHokie's Roadster Build Thread - RT Drop Trunk

  1. #81
    Member VAHokie's Avatar
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    Nothing too noteworthy to post since my last update as my time to work on the car has been limited, but I did manage to get a solid 6 hours this past Saturday to begin fitting and drilling panels. I managed to get both F panels, DS and PS footboxes, firewall, and trans tunnel front vertical wall positioned and drilled (see below). Work will continue this week on the cockpit floors and hopefully finish all fitment/drilling by the end of next week. I still need to pick up an aluminum sheet to fabricate the two upper trunk side walls and possibly a piece along the back trunk wall (still TBD). I also made a trip to FFMetals to pick-up one of their trans tunnel covers as I plan to do a mid-shift and have no interest in having an uneven surface with aluminum patches. It's a nice a high quality piece and Bill's a great guy. Spent a solid 45 minutes talking shop, sharing tips/tricks, etc.

    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

  2. #82
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    Looks good Tony. John, Craig, Henry (another builder) my brother and Dave (old friend) were able to do the first body fitting yesterday, looks pretty good.
    JR
    MK4 complete kit #9059 ordered 1/19/17 delivered 3/23/17, 2015 IRS, Fortes/DART347,TKO 600, hyd clutch, P/S, 12.88 wilwood brakes front and rear, high back kirkey seats, heater/defrost and vintage gauges
    First start and go-cart 4/11/18

  3. #83
    Senior Member phileas_fogg's Avatar
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    Well well well...I was beginning to wonder if you'd abandoned this thread!

    Good to know you're making progress.


    John
    MK IV Roadster #8631
    Ford 302, Holley Terminator EFI, T5z, 3.55 Rear End, IRS, 17” Halibrand Replicas (9” front, 10.5” rear), Nitto 555 G2’s (275/40ZR17 front, 315/35ZR17 rear), Fast Freddie’s Power Steering, F5 Wilwood Brakes, FFMetal’s Firewall Forward, Forte’s Hydraulic Clutch & Throttle Linkage

  4. #84

    Steve >> aka: GoDadGo
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    L-L-Looking Good!
    Please keep in mind that CLECO FASTENERS are your best friend at this stage of your build.
    Also, make sure to run and install your rear electrical harness, fuel and brake lines before you permanently install the pans.
    It makes life a lot easier if you do.
    Good Luck From The Dark-Dart Side!
    Last edited by GoDadGo; 02-27-2019 at 12:14 PM.

  5. #85
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    Quote Originally Posted by jrcuz View Post
    Looks good Tony. John, Craig, Henry (another builder) my brother and Dave (old friend) were able to do the first body fitting yesterday, looks pretty good.
    JR
    Congrats, JR! Big milestone.
    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

  6. #86
    Member VAHokie's Avatar
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    Quote Originally Posted by phileas_fogg View Post
    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!
    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

  7. #87
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    Quote Originally Posted by GoDadGo View Post
    L-L-Looking Good!
    Please keep in mind that CLECO FASTENERS are your best friend at this stage of your build.
    Also, make sure to run and install your rear electrical harness, fuel and brake lines before you permanently install the pans.
    It makes life a lot easier if you do.
    Good Luck From The Dark-Dart Side!
    Thanks, GoDadGo. I'm putting the 50 I have to work, that's for sure. No panels will be installed for awhile and certainly not before the pieces you referenced go on.
    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

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  9. #88
    Member VAHokie's Avatar
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    Panel fitment is 95% complete and before wrapping it up, I wanted to fabricate a few aluminum pieces: firewall brace and upper trunk inside panels. Nothing too crazy here, but enjoyed doing these mods to add some rigidity to the firewall and improve the finish in the trunk. For the firewall brace, I used the provided DS front footbox panel that isn't used as it already had the flanges to butt up against the firewall.

    Here's the panel ready for the first cut - placed painters tape down to avoid scuffing the aluminum.


    And the finished piece installed. Still need to drill a couple of holes to allow for the wiring harness to pass through.


    For the upper trunk inside panels, I ordered a 2' x 2' piece of 6061-T6 aluminum from Aircraft Spruce which was enough to cut three of the panels, allowing a little margin for error (little foreshadowing here). I then traced the previously made template onto the aluminum and proceeded to make the cuts.


    After cutting the DS, I attempted to install it and had the hardest time getting it into place, eventually conceding defeat and cutting the panel in two to slide in from different directions. Here's a pic of the two panels installed - note the vertical cut behind the roll bar mount.


    After drilling and clecoing it in place, it dawned on me that to install this panel you can simply push it in up against the side from the interior vs. trying to slide it from the front to the back (as I was doing before). Duh! This required a few extra cuts, specifically creating a slot for the roll bar mount to slide through, but easy enough. I applied this approach to the PS and voila - success!


    Satisfied with this new approach, I used the remaining material of the 2' x 2' and fabricated another DS panel. I know, I know... it'll be covered by carpet and no one will ever know if I had kept the original in there, but I would and that was reason enough to spend the extra time to do it right.


    Next weekend I'll tackle the RT drop trunk mod and that should bring the panel fitment process to end. I'll then pull everything off, deburring the holes as I go, inventory everything, and begin the process of getting quotes for PC. I was definitely in the PC everything camp in the beginning, but the more time I'm spending with the panels, the more I may just PC those that will be visible in the engine bay. A key driver will be the cost.
    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

  10. #89
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    Good work Tony, I'm jealous. I just spent the week-end getting my rear bumper fitted-up.
    JR
    MK4 complete kit #9059 ordered 1/19/17 delivered 3/23/17, 2015 IRS, Fortes/DART347,TKO 600, hyd clutch, P/S, 12.88 wilwood brakes front and rear, high back kirkey seats, heater/defrost and vintage gauges
    First start and go-cart 4/11/18

  11. #90
    Senior Member phileas_fogg's Avatar
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    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
    MK IV Roadster #8631
    Ford 302, Holley Terminator EFI, T5z, 3.55 Rear End, IRS, 17” Halibrand Replicas (9” front, 10.5” rear), Nitto 555 G2’s (275/40ZR17 front, 315/35ZR17 rear), Fast Freddie’s Power Steering, F5 Wilwood Brakes, FFMetal’s Firewall Forward, Forte’s Hydraulic Clutch & Throttle Linkage

  12. #91
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    Quote Originally Posted by phileas_fogg View Post
    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
    Or move the heater a bit outboard. It is very close, but fits as the template indicates but one of the air outlets comes out right at the 3/4" tubing support. It will work, but very tight.

    Mk4 20th Anniversary #8690 ( #8 of 20 ) Purchased 8/18/18----Build Started 8/19/18
    First Start 11-1-18
    ---- First GoCart 11-7-18
    BluePrint Engines 347ci / TKO600
    Carb / Heater / Heated Seats / Cruise Control / Drop Trunk & Battery

    Build Thread Click Here Gel Coat Driver 1/12/19 - Hit 1000 Miles 3-23-19

  13. #92
    Member VAHokie's Avatar
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    Quote Originally Posted by phileas_fogg View Post
    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.
    Quote Originally Posted by BadAsp427 View Post
    Or move the heater a bit outboard. It is very close, but fits as the template indicates but one of the air outlets comes out right at the 3/4" tubing support. It will work, but very tight.
    No heater planned for the build, just heated seats, so I should be good to go. Appreciate the input though and hopefully it will benefit another builder considering the heater install.
    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

  14. #93
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    After a six week hiatus I got back into the garage this past weekend to pick back up with final panel fitment and to tackle the Russ Thompson drop trunk kit. The kit is high quality and the instructions provided by Russ are very detailed. I still need to do some final trimming on the DS and PS edges (~1/8"), clean up some of the cuts for the cross brace clearance, and drill the holes to mate the drop trunk with the lower trunk floor. Cautionary words for those that are doing this mod: Be sure to follow the instructions about placing the rivet holes close to the edge of the flanges instead of in the center, as well as not placing the corner rivet holes too far into the corner. In both cases, doing so could make it hard to get your rivet gun into position. It's called out in the instructions, but worth repeating. For my application, I needed the corner rivets 11/16" in to account for my rivet gun. Also, Russ provides some rough marks for cutting the cross brace clearance. The one on the rear and PS were pretty close, but the one at the forward DS was off. In fact the relief required ran right through the corner. In looking at a couple of other recent builds, this appears to be true for others. Here's a couple of pics:

    View of the holes close to the flange edge. I don't believe i'll have any issues with the rivets seating, but we shall see.


    Completed trunk. You can see where the DS forward brace clearance is right in the corner of the box.


    Lower trunk installed right after making the cuts.


    Here's a bird's eye view.


    Drop trunk clamped into position.


    View from the PS bottom.


    View from the DS bottom.
    Last edited by VAHokie; 05-07-2019 at 08:39 PM. Reason: Added pic of hole placement on flanges
    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

  15. #94

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    Very nice! Thanks for all the tips on the RT drop trunk. I'm right behind you and will be tackling all the sheet metal shortly so I appreciate all the pointers.
    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

  16. #95
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    Nice work Tony!
    JR
    MK4 complete kit #9059 ordered 1/19/17 delivered 3/23/17, 2015 IRS, Fortes/DART347,TKO 600, hyd clutch, P/S, 12.88 wilwood brakes front and rear, high back kirkey seats, heater/defrost and vintage gauges
    First start and go-cart 4/11/18

  17. #96
    Member VAHokie's Avatar
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    Quote Originally Posted by JohnK View Post
    Very nice! Thanks for all the tips on the RT drop trunk. I'm right behind you and will be tackling all the sheet metal shortly so I appreciate all the pointers.
    Thanks, John. Reach out with any questions; although I'm sure you'll be just fine.

    Quote Originally Posted by jrcuz View Post
    Nice work Tony!
    JR
    Thanks, Jerry. Shoot me a PM when you have some time - would love to hear how the finishing touches on the build are going.
    MKIV Complete Kit #9494 l Carb'd 306 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Hydraulic Clutch, Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Lower Radiator Support, Fan Shroud l Boig Quiet Pipes l 18" Forgestar F14s

  18. #97
    BadAsp427's Avatar
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    Tony, You are coming right along... Won't be all that long now before you'll be looking back and thinking.... That wasn't so bad!!!

    Mk4 20th Anniversary #8690 ( #8 of 20 ) Purchased 8/18/18----Build Started 8/19/18
    First Start 11-1-18
    ---- First GoCart 11-7-18
    BluePrint Engines 347ci / TKO600
    Carb / Heater / Heated Seats / Cruise Control / Drop Trunk & Battery

    Build Thread Click Here Gel Coat Driver 1/12/19 - Hit 1000 Miles 3-23-19

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