Passenger Foot Well Aluminum Question

[rsw81]

Hey guys, I'm prepping and drilling all the aluminum for the passenger foot well on my MkIV. The instructions as usual are somewhat vague. There is a 2" tube frame member that wraps around the outside and front of the foot well. Does the outer aluminum (just in front of the door) rivet into the 2" tube or just to the neighboring aluminum? Seems like it's close enough to rivet to it, but the instructions don't mention it specifically.
Thanks!
Rob

ps: Seems odd that they instruct us to remove all the aluminum when first prepping the car, then reassemble it all with nothing added to this area. Seems better to drill it all while still on the car, then remove, silicone, reassemble in the order of the manual.

[rsw81]

Bump? Insight from those who came before me?

Also, I assume to do all the riveting from the outside in as shown in the manual, but is there any reason not to rivet from the inside out?

[Norm B]

I did put rivets to the outside round tube on the passenger side. Be careful drilling because it is very easy for the bit to walk on the small round tube and snap.
In the engine compartment, where you can see the rivets, I put them from outside to in. The rivets will be hidden by carpet where they would be visible in the footwell. All other areas, where they can’t be seen, i riveted from the easiest direction.
With the passenger footwell I would fit all the panels first and then rivet. I didn’t follow the manuals method of assembly exactly. I marked and drilled all the panels then removed, cleaned and clear coated the visible areas before reassembly. This prevents the messy experience of drilling through the silicone between the panels.

HTH

Norm

[DadofThree]

Riveting for the outside is easier to reach, and the appearance is better from the engine bay.

I did put some rivets into the two inch tube, but not many.

[egchewy79]

Rivet from the outside. the back side of the rivets is an eyesore and you wouldn't want that visible from the engine bay. The carpet covers the inside of the rivets. I did not rivet to the round tube on the bottom of the PS outside wall, just to the adjacent panel from the floor. I think the manual has us remove the panels first so that you can mark where the panels overlap the 3/4 square frame, and predrill your holes without worrying about missing the frame. I don't see why you wouldn't be able to predrill your panel to panel rivet holes, however. One thing to consider before attaching panels for good w/ rivets and silicone...I made cardboard templates of all the panels and labeled them. If you plan on lining the cockpit with a peel/stick material like dynamat, fatmat, kilmat, etc, this makes it infinitely easier to cut your mat. once you have the panels attached, it's a huge pain to crawl in the footbox to measure stuff. I'd recommend putting the sound/heat barrier before installing panels on the DS with the pedals being in the way.

[Avalanche325]

The panels are not placed exactly and aligned correctly on the car from FFR. They are just smacked on there for shipping.

[rsw81]

The panels are not placed exactly and aligned correctly on the car from FFR. They are just smacked on there for shipping.

I can't say for the driver's foot box as I took it apart before looking too closely, but whoever did my passenger foot box must have had their Wheaties that day, because everything was perfectly square, lined up, etc.

[GoDadGo]

Consider buying some double ended bits like the ones shown below:

https://www.jbtools.com/sg-tool-aid-15210-1-8-double-end-drill-bit-10-pack/?gclid=CjwKCAjw1v_0BRAkEiwALFkj5vEEktRiP0PUSJVjiQm stjwq_Ic19RxHE6jg9_IZ6x1Nqn5Xu9KKKBoC3hcQAvD_BwE

They work well and are pretty hardie.

If you want o see rivet placement, then you can see them really well in my very early build video since my panels are painted black:

https://youtu.be/_wnHDNgnNqs

Good Luck & Happy Riveting!

[rsw81]

Consider buying some double ended bits like the ones shown below:

https://www.jbtools.com/sg-tool-aid-15210-1-8-double-end-drill-bit-10-pack/?gclid=CjwKCAjw1v_0BRAkEiwALFkj5vEEktRiP0PUSJVjiQm stjwq_Ic19RxHE6jg9_IZ6x1Nqn5Xu9KKKBoC3hcQAvD_BwE

They work well and are pretty hardie.

If you want o see rivet placement, then you can see them really well in my very early build video since my panels are painted black:

https://youtu.be/_wnHDNgnNqs

Good Luck & Happy Riveting!

Thanks. I bought a handful of shorty 1/8 drill bits from McMaster a while back and have been serving me well. Also bought a pneumatic riveter which has saved my hands already (I work with my hands all day, need to save them when I can). Great thing about the pneumatic riveter, is that my 5 & 7 year old sons can use it and "help" dad with the car.

I noticed on your passenger footbox there are 3 rivets or bolts coming down on the outer edge mid-panel. What are these for?

[GoDadGo]

I noticed on your passenger footbox there are 3 rivets or bolts coming down on the outer edge mid-panel. What are these for?

The three (3) Rivetnuts with the Allen head screws on the top hold my heater core which heats the feet of Mrs. Go-Dad.
The three (3) Rivets on the outer panel secures a bracket that holds one of my speakers which can be viewed from the inside of the foot-box shown below:

https://thefactoryfiveforum.com/album.php?albumid=982&attachmentid=52730
https://thefactoryfiveforum.com/album.php?albumid=982&attachmentid=52729
https://thefactoryfiveforum.com/album.php?albumid=982&attachmentid=52727

For the record, I wanted the radio (Bad Idea) and my wife wanted the heater (Good Idea) so you get the picture.
One thing you truly need to understand about your future is that your boys will both be 100% Motor Heads long before they will be able to drive.

[rsw81]

One thing you truly need to understand about your future is that your boys will both be 100% Motor Heads long before they will be able to drive.

That's the idea! I'm using it as a platform to teach them about cars, but also problem solving across all mediums. Electrical, plumbing, hydraulics, mechanical, etc.