Panel Alignment Questions

[VAHokie]

In adjusting panels for final fitment so that they may be marked, pulled, drilled and sent off to be PC'd, I came across a couple of things I'd like to run by the group.

After repositioning the cockpit backwall it is now sitting lower than it came installed from the factory and I also have a 1/16 difference in the gap between the left and right seat belt slots. Normally wouldn’t worry about this, but the fact that the body rests on it, I’ve been stewing over it. Before making peace with this in believing that the bulb seal will help address any slight inconsistencies, I'd like to get everyone's thoughts.

Here's a pic of the rear of the cockpit wall as delivered from the factory. You can see it sits higher to where the bottom of the seat belt opening is above the crossmember.


But here you can see how I have it positioned the bottom lip now sits below the crossmember. You can also see the slight difference in the gap here.


Additionally, after getting the DS footbox panels positioned, I have one fitment issue where there’s a gap created on the inside of the engine bay towards the back right below the firewall. Anyone else encounter this same issue or have thoughts? Or should I just find comfort in knowing that this will be one of many gaps and this will be covered up from the interior with insulation and carpet?

[j.miller]

1st, no bulb seal goes on the 3ft+or- of the rear cockpit panel (body does not rest on that) .2nd, move that panel with the gap up, around, about so there is no gap. All the aluminum is digital cut so unless the ran short on the aluminum sheet you should be able to find a "happy place"...da bat

[VAHokie]

Thanks, Jeff. For that footbox panel, it was positioned from the factory on the inside of the footbox but protruded towards the trans tunnel to the point it didn't appear to be positioned right. Can you confirm it should be on the outside of the footbox as it is now?

[BB767]

For what it's worth, my rear cockpit panel fit the same way. After firmly attaching it to the floor it was to short, I think I actually had to enlarge the seat belt holes slightly. In the end the overall height was fine, it lines up perfectly with the body.

[Papa]

I believe the rear cockpit panel looks correct as you are showing it. You want some of that square tube along the bottom openings for the seat belt to keep the belts from rubbing on that sharp aluminum. I also used some of the small edge trim to finish out the other three sides of the opening.



The foot box fitment doesn't look right.

I had to do a bit of trimming to get mine to fit, but I put that corner on the inside.

[cv2065]

On the gap below the firewall, I 'think' I know where you are talking about. I think its common as I've seen it in other builds. I addressed it with a piece of panel that I cut to size so that I wouldn't get engine heat coming out of it.

Here's a before and after looking from the inside of the cockpit.

[VAHokie]

For what it's worth, my rear cockpit panel fit the same way. After firmly attaching it to the floor it was to short, I think I actually had to enlarge the seat belt holes slightly. In the end the overall height was fine, it lines up perfectly with the body.

I believe the rear cockpit panel looks correct as you are showing it. You want some of that square tube along the bottom openings for the seat belt to keep the belts from rubbing on that sharp aluminum. I also used some of the small edge trim to finish out the other three sides of the opening.



The foot box fitment doesn't look right.

I had to do a bit of trimming to get mine to fit, but I put that corner on the inside.

Thanks, guys. On the trunk I was thinking the same thing about helping mitigate the bottom of the belts rubbing against the aluminum.

Dave, for the footbox panel, mine came installed as you have it on the interior of the car but had that big overlap like you where it protruded past the trans tunnel. I'll adjust back and mark to cut as you did. Your mark looks about the same that I'll have to cut off.

[VAHokie]

On the gap below the firewall, I 'think' I know where you are talking about. I think its common as I've seen it in other builds. I addressed it with a piece of panel that I cut to size so that I wouldn't get engine heat coming out of it.

Here's a before and after looking from the inside of the cockpit.

Thanks, cv2065. I have no doubt I'll be putting that extra DS footbox forward panel to good use in making small patches to fill gaps.

[Papa]

On the gap at the top of the panel, I siliconed it and applied the Thermo-Tec completely covering it from the inside. The carpet goes all the way up and covers it completely from an aesthetics perspective.

Dave

[CraigS]

VA, ck w/ John on some trim to go around the seat belt opening.

[RJD]

Play around with the panel overlap points. For example, where Papa has his corner on the inside, I have mine outside and ended up with about a 1/16" gap at the footbox top. I'm planning to use the below caulk for some gaps that can't be addressed by seam sealers, silicone, or by adjusting panels.


FC4161EB-0ED2-4345-805E-52D8E62F34C0.jpg

[Avalanche325]

Keep in mind that FFR just attaches the panels for shipping purposes. They are not positioned accurately. They are overlapped the correct way.

[VAHokie]

Keep in mind that FFR just attaches the panels for shipping purposes. They are not positioned accurately. They are overlapped the correct way.

I went ahead and moved the overlap for the panel question back to the interior as it was positioned from FFR and trimmed to fit - should be good to go. On a related note, I've moved onto the PS footbox and noticed on the bottom that many of the overlaps are on the exterior as installed from FFR (see below) which is also how they appear in the lone picture in the manual. This is different than the DS footbox which has them all tucked in for a clean appearance. Does this jive with how it's positioned on yours?

[Papa]

I went ahead and moved the overlap for the panel question back to the interior as it was positioned from FFR and trimmed to fit - should be good to go. On a related note, I've moved onto the PS footbox and noticed on the bottom that many of the overlaps are on the exterior as installed from FFR (see below) which is also how they appear in the lone picture in the manual. This is different than the DS footbox which has them all tucked in for a clean appearance. Does this jive with how it's positioned on yours?

Both my DS and PS foot boxes are as you show with the floor panel supported by the sides.

Dave

[RJD]

Both bottoms on mine jive with Papa's and your picture of the PS side footbox.

[cv2065]

I went ahead and moved the overlap for the panel question back to the interior as it was positioned from FFR and trimmed to fit - should be good to go. On a related note, I've moved onto the PS footbox and noticed on the bottom that many of the overlaps are on the exterior as installed from FFR (see below) which is also how they appear in the lone picture in the manual. This is different than the DS footbox which has them all tucked in for a clean appearance. Does this jive with how it's positioned on yours?

I matched mine on both sides for the 'clean' look. Once its siliconed and riveted, I doubt it matters much.

[VAHokie]

Thanks, all. For reference, here's a pic of the DS footbox bottom, where the angled bottom of outside sidewall overlaps on top of the angled part on the bottom floor.

[Papa]

Yep - Same overlap on mine. When you get ready to put that side panel on, be careful drilling so that you don't gouge the powder coat on the round tube. I typically use one of these:

https://www.northerntool.com/shop/to...9271_200449271

301101_2000x2000.jpg

Dave

[VAHokie]

Yep - Same overlap on mine. When you get ready to put that side panel on, be careful drilling so that you don't gouge the powder coat on the round tube. I typically use one of these:

https://www.northerntool.com/shop/to...9271_200449271

301101_2000x2000.jpg

Dave

Thanks, Dave. Appreciate the heads up.