New Member, Perhaps An Old Question: Build Sequencing?

[MBDSLPWR]

Greetings all. I'll try to be concise.

Am gearing up for a potential build. In preparation, I visited FFR a couple weeks ago, observed their operations, talked with their folks, bought a MKIV print manual for review, and joined these forums to build my knowledge base.

Despite my search efforts, I'm -thus far- unable to track down clear project plans which discuss sequencing the build.

Primarily, I'm seeking information on the "can't do this after that," "must do this before that," "better to delay this," and "better to start this earlier versus later" items.

I do not wish to reincarnate an existing thread here. Should this information exist, please point me in the right direction and I'll quietly carry on with my research.

Many thanks.

MBDSLPWR

[GoDadGo]

I've been following the book, except my modifications, and so far it is coming along nicely.
You may want to go to the build school because I've had a friend go and he loved it, but chose to NOT order a kit.
He said if he did decide to order a kit he might just go back to the build school for a refresher course because it was so much fun.
Check out the attached video and see if this might be of interest to you:

https://youtu.be/MKsh3yTzGYA

[Ray]

http://www.ffcars.com/#/topics/168897?page=1&_k=ai4a3i

This is in the FAQ section of the "other" site

Ray

[wareaglescott]

There is a lot of flexibility on how to proceed. The manual goes in a pretty good order. My limiting factor on following the manual was parts availability. I started following the book until I got to a point I was stopped waiting for a backordered part. Everyone has a different experience and time tables with back orders so that will be the unknown. At one point I had multiple areas of the car about 90% done waiting for a part to show up. When it did I was able to finish that area and mark it off my list. I had zero experience coming into this but once I got going it became pretty apparent what needed to be done before what. I found it useful to make a checklist of sorts. When I got to a point in the manual and I did not have what I needed to complete that step I had a separate list I would write down the page number, what I was missing, and what I needed to do. Then later on when those parts came in and I completed that step I could cross it off my list. Helped to make sure I did not skip any important steps.

A few specific tips I have come across that may be what you are looking for:

A good tip I got on aluminum panels was do not do a final install until you absolutely have to. The more of those that are permanently installed the more items on the car will be harder to access. This is particularly important for the side and top of the drivers footbox. Clecos are extremely handy for temporarily holding panels in position.
Guys do panels differently but I found it worked good to drill them all as much as I could when I was taking them off the frame for the first time. I got about 95% of the holes drilled as they came off and then took them all to the powder coater. Then as I was reassembling I never had to do much more panel work or have any sort of wait for them to be coated.

I find the search function on this forum hard to use and find exactly what I am looking for. If you have questions fire away. Great community of people here that are happy to help you out.

[Jeff Kleiner]

...Don't install the trunk floor permanently until after you have secured the rear cockpit wall...

Actually that is backwards---don't install the back wall until after you have riveted the trunk floor.

MBDSLPWR,
Your question is kind of broad; can you be more specific? It is possible to jump back and forth on many items when necessary due to convenience, supply or space issues. My general order is:

---build suspension
---run brake and fuel lines (a few aluminum panels need to be in place when doing this)
---install aluminum but leaving off the top and outside of the driver's footbox
---install wiring
---install drivetrain and cooling system
---initial body fit
---bodywork & paint
---insulation & carpet (body off)
---final body installation and trimout

Nothing is set in stone but that works for me.

Jeff

[Larry Johnson]

A related question of sorts... Is there a sequential list of all the parts included in the Mark IV Complete kit? I find myself picking up a bag of bolts (say number 12345) and having to go page by page in the shipping list to determine what they are for.
It would be great if a list existed that showed all the parts in numerical order.
It also would have been great if I'd organized the parts better when I unpacked but thats another story.

[wareaglescott]

Actually that is backwards---don't install the back wall until after you have riveted the trunk floor.

MBDSLPWR,
Your question is kind of broad; can you be more specific? It is possible to jump back and forth on many items when necessary due to convenience, supply or space issues. My general order is:

---build suspension
---run brake and fuel lines (a few aluminum panels need to be in place when doing this)
---install aluminum but leaving off the top and outside of the driver's footbox
---install wiring
---install drivetrain and cooling system
---initial body fit
---bodywork & paint
---insulation & carpet (body off)
---final body installation and trimout

Nothing is set in stone but that works for me.

Jeff

Thanks for correcting me Jeff. Posted that to early this morning and had a brain cramp! I am deleting that from my previous post so there is no confusion.

[edwardb]

A related question of sorts... Is there a sequential list of all the parts included in the Mark IV Complete kit? I find myself picking up a bag of bolts (say number 12345) and having to go page by page in the shipping list to determine what they are for.
It would be great if a list existed that showed all the parts in numerical order.
It also would have been great if I'd organized the parts better when I unpacked but thats another story.

Not aware of any such list. Wouldn't it be easier to do the opposite? Only look for a part number (e.g. bag of bolts) when the build sequence calls for their use? After the inventory, I leave all the parts in the boxes as shipped. If I add or move anything or as backordered stuff arrives, I mark up the list so it's always accurate. Then use the packing list to find specific items. Stuff is generally grouped together, but not always.

I'm with Jeff on the sequence he shows. The only caveat I would add, especially for new builders, is for brake, fuel and wiring keep an eye on the aluminum panels and where they're going to fit. Make sure you're hanging tubing and wiring in available space as well as where it can be serviceable when you're done.

[BEAR-AvHistory]

Followed the book for the most part. One thing I found useful in addition to what's listed above I also left the PS outside footbox panel off till I had the carpet fitted & Installed.

[MBDSLPWR]

Jeff - I'd like to ask more specific questions, but being so new, it's all a case of "I don't know what I don't know." With these initial responses and some more digging, I can (and will) ask more pointed questions.

To all - thanks for the useful information so far.

MBDSLPWR

[Al_C]

OK, I'll add my 2 cents. On parts, I find that I have to go back to the original inventory frequently. I labeled the plastic bags of hardware as to what they are (i.e. header bolts, fuel parts, etc.) so it's easier to understand. I, too, sought a numerical list, but other than me creating a spreadsheet of parts (I didn't), there is no consolidated parts list other than your packing (by shipping box) list. Relative to the sequence item, I tried to stick with the sequence in the manual, except where Build School advice differed. I'm beginning to think it doesn't make that much difference, as I end up doing and undoing so many times. But what the heck - isn't that the fun part?

[MBDSLPWR]

Anyone have an example build spreadsheet I could borrow as a start point?

Pre-empting a legitimate question from elsewhere: "Do you really want to know the costs?" Not overly concerned about costs, but -DO- want to track options and suppliers and prioritize options within a budget. Seems a key planning activity.

[JIMOCO]

I have an excel spread sheet that I used to record every purchase I made during the construction of my car. I have a tab that compares budget to actual and a tab that summarizes the purchases by type of item such as tools, hardware, supplies, parts (such a battery, turn signals ect.). Some may say I'm anal but the reality is I am an accountant. I would be happy to share it with you. Send me a PM with your email and I will send it off.

[MBDSLPWR]

JIMOCO - Thanks. PM en route.

[Straversi]

if you are building it per the book, the sequence in the manual is a good guide. Each time you add an option or deviate from the book it can change the sequence a bit. I was pretty lucky with back ordered parts, meaning I had a few but they never interfered with my sequence. Even with parts issues there is always something that you can be working on. I think if you are powder coating or doing something special with your body panels you will need to think your steps through carefully and mock up assemblies more so than if you are following the book and riveting on bare aluminum panels. Have fun. Each choice you make, makes your finished project and your build experience unique.
-Steve

[Norm B]

I followed the manual except for the previously mentioned trunk floor/rear cockpit panel installation and I ran the rear wiring harness, brake and fuel lines before the cockpit and trunk aluminum were permanently installed.

HTH

Norm

[Dave Howard]

The great people at FFR put the assembly manual together for the benefit of the builder. Follow the assembly manual in sequence from the front to back and you won't find yourself built into a corner cause you thought you could deviate and do it better. Now, before I get "Trumped" for that comment .... yes you can jump around some, but the 1st time builder will benefit from following the manual.

[GoDadGo]

Like Norm B, I installed the brake and fuel lines, rear harness and drilled my roll bars before installing the aluminum in the trunk and cockpit.
Other than that I've pretty much done the build by the book except for the alternative engine, transmission, and rear end.
I did move the wiring harness to the passenger side, to keep the driver's foot box clean, so the blinkers had to be flipped and I had to extend the brake pedal light switch wire.
While these changes may be off the deep end, the build sequence has been in the order of the book.
Shown below is pretty much where I am, so if I can do it, then so can you:

https://youtu.be/_wnHDNgnNqs