Still drilling, but fabbing too!

[MPTech]

Big THANKS to Rich for helping me turn my big sheets of aluminum into smaller bent pieces.

Also Thanks to Don Payne for a great template!!

Using Don's template, we fabbed up a new Passenger Footbox.
http://mk3build.com/library/PassengerFootbox.pdf

one correction, we did have to make an adjustment to the outside panel (page 4), the measurements were off in the plans and it wouldn't fit correctly. If I remember correctly (Rich, please correct me if I'm wrong). On the outside panel (towards the body) we had to extend the total length about 3/4" (the total length to the bend should be 17.75" (not 17" ( 2.25 + 14.75"). The 90* side panel should be 11.25 (not 11.5") and the top diagonal should be about 6.5192", to match the Back Wall (page 1, look at the length of the right side and diagonal there, 11.25" and 6.5192" respectively). The original panel (per the template) was off. We must have measured it about a dozen times. So we made our adjustments and fab'd a new piece, Fit like a Glove!! We mocked this up on Rich's mk3 and it improved his passenger footbox CONSIDERABLY, about 5" deeper and almost 4" wider (if I remember correctly). The mk4 footbox is bigger already, but this did add a couple inches in depth and almost 2" wider. Additionally, it straightens out the left side of the footbox so it's more comfortable too.

I got home last night, about 9pm, from Rich's but I was so excited, I stayed up till almost 1am mocking it in place. I assembled, drilled and screwed the box together on my workbench, then clamped and cleco'd it in place on the chassis. I would have finished last night if I hadn't broken my drill bit (I got tired and snapped it off drilling the main rail).

(the panels are aluminum, they just have the white protective plastic still on them).
http://i9.photobucket.com/albums/a78/MPTech/IMG_0102.jpg

http://i9.photobucket.com/albums/a78/MPTech/IMG_0103.jpg

http://i9.photobucket.com/albums/a78/MPTech/IMG_0104.jpg

http://i9.photobucket.com/albums/a78/MPTech/IMG_0105.jpg

http://i9.photobucket.com/albums/a78/MPTech/IMG_0106.jpg

http://i9.photobucket.com/albums/a78/MPTech/IMG_0107.jpg

http://i9.photobucket.com/albums/a78/MPTech/IMG_0108.jpg


Rich was a GREAT help with cutting, bending, and test-fitting these panels and it went together great when I got home!
Again, BIG THANKS to Rich! and a big THANKS to Don for some truly great templates.

My wife is going to like this, she just doesn't know it yet!
I just have my fingers crossed that there is no header clearance issues, but I'm relatively confident it will be a good fit.

I highly recommend this mod, but it will be difficult without a metal brake. I think Rich's was 36"!

[Pierre B]

Very nice sheet metal work, and I am sure your passenger(s) will welcome the added foot room. For me, the idea of widening the passenger footbox has always been somewhat tricky. In my MKII, I have a mild donor 302 with MAC Shorty headers, and the header to footbox clearance on the driver's side is really very tight in one spot. Widening the passenger box may well create that same condition on the other side. Since I have done a reasonable job of insulating the footbox sidewalls, I have no heat issue, but others with larger engine setups may feel differently, or they may just not consider that a problem. In my case, I have had to, from time to time, tighten the header bolts and change plugs, so wrench and maintenance clearances on the sides of the engine are a concern. Of course, the building process enables us to make modifications (for insulation or maintenance clearances, for example) all the way through. During the building process, we deal with and address an issue once or maybe twice and it's done. But later maintenance concerns keep coming back over and over. Just a friendly caution, and keep up the good work. You are well on your way to building a car of which you will be very proud.

[riptide motorsport]

Fantastic work, great feeling the adrenaline flowing and progress being made isn't it!!!!!!!!!!!

[E-Ticket Ride]

Great execution. Guess I need to find someone local with a sheet metal shear and brake I can borrow...
I haven't tried that (SM work) since about the 8th grade - that was a looooong time ago.

I forget, what engine are you planning on running?
CL

[MPTech]

I'm running a 302 w/4-into-4 BBK headers. I don't think you'll have the header clearance with the Coyote, to allow the PS FB mod. I gained 1 1/2 to 2" toward the engine, I think you's will be much tighter. The mk4 is already bumped out to the body about at far as it can go, I think.

[Lynnhowlyn]

Hey MPTech -
It's been a couple months or so since you did the PS footbox modification. Any updates on "ripple effects" - e.g. header clearance or ???

When I rode in 3.1 a couple weeks ago (my 1st ride - and what a rush!!!), I was sorta uncomfortable with the size of the PS footbox, and am considering doing your (Don's) mod to enlarge my Mk4 PS footbox.

Any updates or learnings you can share will be hugely appreciated.

Many thanks

Lynn

[Gumball]

Very nice - great work and likely quite rewarding to both you and all your future passengers.