Panel Order

[CRAZYBOB]

Looking at the MK4 build manual there are over 70 panels to get powder coated. If the powder coating covers any markings how do you keep all of these in some type of logical order? I could see this turning into a horrible puzzle. Especially if you could invert them or mix them front to back. Suggestions?

10551 ALUMINUM PANEL, RH FOOTBOX, VERTICAL WALL, OUTSIDE WALL 1
10554 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALLS, OUTSIDE 1
10557 ALUMINUM PANEL, LH COCKPIT FLOOR, W/TUNNEL WALL 1
10558 ALUMINUM PANEL, RH COCKPIT FLOOR, W/TUNNEL WALL 1
10823 ALUMINUM PANEL, REAR COCKPIT VERTICAL WALL (BEHIND SEATS) 1
10853 ALUMINUM PANEL, RH FOOTBOX, TOP 1
10858 ALUMINUM PANEL, LH FOOTBOX, TOP/OUTSIDE SECTION 1
10859 ALUMINUM PANEL, LH FOOTBOX, TOP/INSIDE SECTION 1
10904 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALL, FRONT 1
10905 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALL, INSIDE 1
12806 ALUMINUM PANEL, TRANSMISSION TUNNEL FRONT VERTICAL WALL 1
12985 ALUMINUM PANEL, LH FOOTBOX, DROPPED FLOOR 1
13138 ALUMINUM PANEL, RH FOOTBOX, VERTICAL WALL, FRONT WALL 1
13139 ALUMINUM PANEL, RH FOOTBOX, VERTICAL WALL, INSIDE WALL 1
13634 ALUMINUM PANEL, RH FOOTBOX, DROPPED FLOOR 1
10559 ALUMINUM PANEL, FIREWALL 1
10863 ALUMINUM PANEL, RH ENGINE BAY WALL "F" 1
10864 ALUMINUM PANEL, LH ENGINE BAY WALL "F" 1
10963 ALUMINUM PANEL, RH FIREWALL EXTENSION 1
10560 ALUMINUM PANEL, TRUNK FLOOR, FRONT SECTION 1
10561 ALUMINUM PANEL, TRUNK FLOOR, REAR, MAIN CARGO AREA 1
10870 ALUMINUM PANEL, LH/RH TRUNK WALL REAR SIDE COVER PANEL 2
13635 ALUMINUM PANEL, RH TRUNK WALL, FRONT 1
13636 ALUMINUM PANEL, LH/RH TRUNK WALL, REAR 2
13637 ALUMINUM PANEL, LH TRUNK WALL, FRONT 1
14585 ALUMINUM PANEL, LH REAR SPLASH GUARD 1
14586 ALUMINUM PANEL, RH REAR SPLASH GUARD 1
10563 ALUMINUM PANEL, TRANSMISSION TUNNEL TOP COVER 1
10906 ALUMINUM PANEL, U-JOINT ACCESS PANEL, (REAR TUNNEL COVER) 1
13246 ALUMINUM PANEL, LH TRANSMISSION TUNNEL, REAR CORNER 1
13247 ALUMINUM PANEL, RH TRANSMISSION TUNNEL, REAR CORNER 1
13641 ALUMINUM PANEL, LH COCKPIT WALL, UNDER DOOR, SIDE 1
13642 ALUMINUM PANEL, RH COCKPIT WALL, UNDER DOOR, SIDE 1
13799 ALUMINUM PANEL, RH SIDE COCKPIT WALL, UNDER DOOR, TOP 1
13803 ALUMINUM PANEL, LH SIDE COCKPIT WALL, UNDER DOOR, TOP 1
14578 ALUMINUM PANEL, LH COCKPIT REAR CORNER, UPPER SPLASH COVER 1
14579 ALUMINUM PANEL, RH COCKPIT REAR CORNER, UPPER SPLASH COVER 1
14580 ALUMINUM PANEL, LH COCKPIT REAR CORNER, LOWER SPLASH COVER 1
14581 ALUMINUM PANEL, RH COCKPIT REAR CORNER, LOWER SPLASH COVER 1
10861 ALUMINUM PANEL, LH SPLASH GUARD 1
10862 ALUMINUM PANEL, RH SPLASH GUARD 1
10865 ALUMINUM PANEL, FRONT NOSE FLOOR (optional, see cowling) 1
10907 ALUMINUM PANEL, LH FRONT NOSE WALL (optional, see cowling) 1
10908 ALUMINUM PANEL, RH FRONT NOSE WALL (optional, see cowling) 1
12273 ALUMINUM PANEL, ENGINE HARNESS BLOCK-OFF PLATE 1
12407 ALUMINUM PANEL, DASH HARNESS BLOCK-OFF PLATE 1
10566 ALUMINUM MOUNT, DASH/SWITCH (FOUR WAY FLASHERS) 1
10638 ALUMINUM MOUNT, DASH/SWITCH (HEADLIGHT) 1
12959 ALUMINUM PANEL, TRANS. TUNNEL COVER BLOCK-OFF PLATE W/O HOLE 1
13140 ALUMINUM PATCH COVER, LARGE HALF 1
13141 ALUMINUM PATCH COVER, SMALL HALF 1
14057 ALUMINUM PANEL, TRANS. TUNNEL COVER BLOCK-OFF PLATE W/HOLE 1
14733 ALUMINUM PANEL, DRIVER FOOTBOX, FRONT PATCH COVER 1

OTHER PIECES
14624 Fuel tank mounting straps 2
Breeze battery box 1
Breeze battery box angle brackets 2
Breeze fan shroud 1
Breeze seat bottom DO NOT POWDER COAT THREADED RODS 2
Breeze seat top 2
********** side louvers (or match paint) 2
Dark Water door sill trim 2
Breeze hinge components
Low J-hinge 2
High J-hinge 2
H-angle, small 2
H-angle, long 1

[David Hodgkins]

Pictures. Lots and lots of pictures!

I marked the ovelap on all or the panels, in addition to all the places they touch the chassis. I then took pictures of everything, before I removed them. For example:

http://ffroadster.com/images/aluminumpanels/AluminumPanel001.jpg

Then I marked the center line of every place they met a 3/4" tube, marked even-spaces, and got to drilling. Then, section by section, and using the pics for reference, I put the panels back on the chassis and drilled the holes into the body and drilled the aluminum-to-aluminum connections. THEN you can take the panels off and have them powder coated. In my case, I spent HOURS AND HOURS doing this to my panels:
http://ffroadster.com/images/aluminumpanels/PolishedFPanel5-800.jpg

Then reference the pics you took before deconstruction and start putting panels back on the chassis...

HTH,

:)

[DougR]

I did pretty much the same thing as David did (polished mine also) and I left markings where the seams overlap with info that would help me get everything back in place and just didn't polish those spots. Ask the shop where you will get your powder coating done and ask if you could mark and then mask areas like this (that won't show).

[Cobra79]

I created an updated list of all the panels. I have attached the list in excel xls and adobe pdf formats (inside zip file).

Part # Description Qty

COCKPIT
10554 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALL, OUTSIDE WALL 1
10551 ALUMINUM PANEL, RH FOOTBOX, VERTICAL WALL, OUTSIDE WALL 1
10557 ALUMINUM PANEL, LH COCKPIT FLOOR, W/TUNNEL WALL 1
10558 ALUMINUM PANEL, RH COCKPIT FLOOR, W/TUNNEL WALL 1
10823 ALUMINUM PANEL, REAR COCKPIT VERTICAL WALL (BEHIND SEATS) 1
15020 ALUMINUM PANEL, LH COCKPIT REAR CORNER 1
15021 ALUMINUM PANEL, RH COCKPIT REAR CORNER 1
10858 ALUMINUM PANEL, LH FOOTBOX, TOP/OUTSIDE SECTION 1
10859 ALUMINUM PANEL, LH FOOTBOX, TOP/INSIDE SECTION 1
14719 ALUMINUM PANEL, LH FOOTBOX, TOP/INSIDE SECTION (4.6 ONLY) 1
10904 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALL, FRONT (MUSTANG PEDALS) 1
15142 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALL, FRONT (WILWOOD PEDALS) 1
10905 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALL, INSIDE 1
14718 ALUMINUM PANEL, LH FOOTBOX, VERTICAL WALL, INSIDE (4.6 ONLY) 1
12985 ALUMINUM PANEL, LH FOOTBOX, DROPPED FLOOR 1
12806 ALUMINUM PANEL, TRANSMISSION TUNNEL FRONT VERTICAL WALL 1
10853 ALUMINUM PANEL, RH FOOTBOX, TOP 1
15015 ALUMINUM PANEL, RH FOOTBOX, TOP/OUTSIDE 1
13138 ALUMINUM PANEL, RH FOOTBOX, VERTICAL WALL, FRONT WALL 1
13139 ALUMINUM PANEL, RH FOOTBOX, VERTICAL WALL, INSIDE WALL 1
13634 ALUMINUM PANEL, RH FOOTBOX, DROPPED FLOOR 1
10563 ALUMINUM PANEL, TRANSMISSION TUNNEL TOP COVER 1
10906 ALUMINUM PANEL, U-JOINT ACCESS PANEL, (REAR TUNNEL COVER) 1
14583 ALUMINUM PANEL, LH TRANSMISSION TUNNEL, REAR CORNER 1
13247 ALUMINUM PANEL, RH TRANSMISSION TUNNEL, REAR CORNER 1
14582 ALUMINUM PANEL, LH COCKPIT WALL, UNDER DOOR, SIDE 1
13642 ALUMINUM PANEL, RH COCKPIT WALL, UNDER DOOR, SIDE 1
13803 ALUMINUM PANEL, LH SIDE COCKPIT WALL, UNDER DOOR, TOP 1
14584 ALUMINUM PANEL, RH SIDE COCKPIT WALL, UNDER DOOR, TOP 1
10566 ALUMINUM MOUNT, DASH/SWITCH (FOUR WAY FLASHERS) 1
10638 ALUMINUM MOUNT, DASH/SWITCH (HEADLIGHT) 1
12959 ALUMINUM PANEL, TRANS. TUNNEL COVER BLOCK-OFF PLATE W/O HOLE 2
14057 ALUMINUM PANEL, TRANS. TUNNEL COVER BLOCK-OFF PLATE W/HOLE 1
14733 ALUMINUM PANEL, DRIVER FOOTBOX, FRONT PATCH COVER 1
12274 ALUMINUM PANEL, TRANSMISSION HARNESS BLOCK-OFF PLATE 1

ENGINE BAY
10559 ALUMINUM PANEL, FIREWALL 1
10963 ALUMINUM PANEL, RH FIREWALL EXTENSION 1
10864 ALUMINUM PANEL, LH ENGINE BAY WALL "F" 1
10863 ALUMINUM PANEL, RH ENGINE BAY WALL "F" 1
10861 ALUMINUM PANEL, LH SPLASH GUARD 1
14587 ALUMINUM PANEL, RH SPLASH GUARD 1
10865 ALUMINUM PANEL, FRONT NOSE FLOOR (optional, see cowling) 1
10907 ALUMINUM PANEL, LH FRONT NOSE WALL (optional, see cowling) 1
10908 ALUMINUM PANEL, RH FRONT NOSE WALL (optional, see cowling) 1
12273 ALUMINUM PANEL, ENGINE HARNESS BLOCK-OFF PLATE 1
12407 ALUMINUM PANEL, DASH HARNESS BLOCK-OFF PLATE 1
13713 ALUMINUM PANEL, ENGINE BAY PASS. "F" BLOCK-OFF PLATE 1
13806 ALUMINUM PANEL, BRAKE MASTER CYLINDER BLOCK-OFF PLATE 1

TRUNK
10560 ALUMINUM PANEL, TRUNK FLOOR, FRONT SECTION 1
15222 ALUMINUM PANEL, TRUNK FLOOR, REAR, MAIN CARGO AREA 1
15223 ALUMINUM PANEL, LH/RH TRUNK WALL REAR SIDE COVER PANEL 2
15402 ALUMINUM PANEL, LH OUTSIDE TRUNK WALL 1
15403 ALUMINUM PANEL, RH OUTSIDE TRUNK WALL 1
14810 ALUMINUM PANEL, LH SHOCK TOWER BLOCK-OFF PLATE (IRS ONLY) 1
14811 ALUMINUM PANEL, RH SHOCK TOWER BLOCK-OFF PLATE (IRS ONLY) 1
14585 ALUMINUM PANEL, LH REAR SPLASH GUARD 1
14586 ALUMINUM PANEL, RH REAR SPLASH GUARD 1
15016 ALUMINUM PANEL, FUEL STRAP BLOCK-OFF PLATE 1

MISC
33488 RIVET SPACING TOOL 1

[68GT500MAN]

Just a question, why are you going to coat panels that get covered by carpet or never seen?
Doug

[first time builder]

That has to cost a small fortune to PC all those panels. Have you gotten a price ?

Kenny

[edwardb]

That has to cost a small fortune to PC all those panels. Have you gotten a price? Kenny

Had all the panels PC'd for both of my builds. Local shop I used charges around $600 for an FFR build. He's done several. I've heard others quote similar amounts. Not cheap. But if you look at the alternatives (and think about the time required) it's not bad for a very durable and good looking finish.


Just a question, why are you going to coat panels that get covered by carpet or never seen? Doug

There are only a few parts that are completely covered. Most have at least one side showing, edges, etc. I asked the shop where I did mine about not coating unseen sides. Said the price would be the same either way. The additional labor to keep it all straight he said was a wash, if not more. The extra amount of powder isn't expensive. The oven time is the same either way. Other experiences may vary, but that was mine.


Looking at the MK4 build manual there are over 70 panels to get powder coated. If the powder coating covers any markings how do you keep all of these in some type of logical order? I could see this turning into a horrible puzzle. Especially if you could invert them or mix them front to back. Suggestions?

Honestly, it's not that bad. Really. Nearly all the parts will only go in one way. And once you drill all the holes and fit, for sure they only go one way. I do mine in sections. PS footbox. DS footbox. Cockpit. Trunk, and so on. Probably the hardest part is keeping track of what edge goes on top, bottom, etc. Just keep some notes or take pictures as you mock it for the few cases where this isn't obvious.

[Bren]

That has to cost a small fortune to PC all those panels. Have you gotten a price ?

Kenny

To echo edwardb, I got a quote from a powder coater who does automotive stuff for $600 for everything. I ended up going to an industrial powder coater that used left over, industrial grade du pont paint and only charged me labor, $200. I got all panels powder coated.

Powder coating everything is not much more than powder coating only what is seen.

[Bren]

On the issue of panel order, by the time I got the panels off to powder coating, they had been on and off the car so many times that I knew visually where each panel went. As to the order, I just followed the manual each time and looked at the pictures to figure out what goes on top. I took a bunch of pictures, but never used them.

[MVRight]

Ditto, took a lot of pictures before removal, but realistically, not too much problems figuring what goes where. I didn't powder coat, some for the cost, but other reason of fitting and drilling holes first before sending out for powder coating. Some panels required some tweaking to get to fit.

[edwardb]

...but other reason of fitting and drilling holes first before sending out for powder coating. Some panels required some tweaking to get to fit.

Correct. That's the right build sequence if finishing the panels. Trial fit the panels, drill holes using Cleco's to hold panels in place as you go. Like this:

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Update%2004042013/th_IMG_2043_zpsd3a7157e.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Update%2004042013/IMG_2043_zpsd3a7157e.jpg.html)

Then remove, finish, and complete final installation with adhesive and rivets. Generally, this same sequence would be followed for any finishing method. PC or not. Once they are finished, they should be ready to drop in. I've seen a few build threads where guys have painted the completed assembly, e.g. with the panels in place. Another choice but IMO a trade-off in the amount of work and I just like the durability and look of PC.

True enough some "adjustment" is required at times. Whether it's slightly tweaking a bend, trimming a bit, whatever. Three comments though. FWIW, I found the fit of the MK4 panels to be better than the Mk3. Use the shipping locations from FFR (held in with sheet metal screws) as a starting point. But don't be surprised if not the exact location. Finally, if something doesn't seem to fit right, check and re-check the instructions and what you're doing before bending or trimming. It could be you're trying to assemble it incorrectly. Ask me how I know that.

[VdubJoe]

I did just the engine bay and a couple other's. All others coated with Lizard skin or sharkhide. Mine was 600.00 but included prepping, primered , silver metallic coat and then a clear all 3 powder.
Fitted then drilled then had coated. Took a lot of pics.

Joe