trimming panels to fit

[jrohrig]

My kit is set to arrive in less than 2 weeks. I went to the build school over 2 years ago, (bad timing on my part, but oh well) and yesterday, I was reviewing the notes I took. One of the first things I wrote down was the following, and I can't for the life of me remember exactly what it means. Maybe someone can help me figure it out:

"Make sure aluminum panels have a 3/8s inch gap prior to removing the body. Mark panels with a sharpie. (especially the back panel (cockpit) behind the seats, side back panels next to door, and the side parts of the firewall area panels where the mirrors go). After the body is removed, cut the panels at that line so the body fits."

My best guess is that there is supposed to be a gap between the under side of the body and the top of the panels. Is everyone supposed to cut these panels or was this just unique to that build school car? Thanks

[CDXXVII]

There is supposed to be a gap to leave room for the bulb seal. You can refer to the manual to see all the placed that get bulb seal.

Having said that, I did not have to trim anything with regards to the panels that came pre installed on the chassis. The only panels I remember having to trim later in the build were the elephant ears.

It can't hurt to take a good look at all the panels prior to removing the body. Go ahead and mark up questionable panels for review later.

Take a bunch of photos to remind you as to which aluminum mating surface goes on top and which ones go below. Hope this makes sense


Enjoy the build

[scrubs]

I went to the school too, but did no trimming until body fitment.

Def mark every place the chassis meets aluminum for easy locating of rivet holes.

[Dave M]

Back when built mine it was standard practice to lay a sharpie marker flat against the inside of the body and run it along marking the panels. This cut line left an all but perfect gap to accept the bulb seal.

[edwardb]

This used to be a practice that was widely recommended, e.g. set the body on without bulb seal and mark interference with a Sharpie. I'd highly recommend not doing this on current new builds. At least not as the first step. Fit and mount the body with the bulb seal making sure to have it positioned exactly right, e.g. front/back and side/side. Only trim the aluminum if necessary. I've done three Roadster builds (1 Mk3 and 2 Mk4's) with little/no trimming required. In my experience, the aluminum parts, especially as currently delivered, fit quite well. Trimming should be the last resort once all other options are exhausted. Not the first.

[Jeff Kleiner]

This used to be a practice that was widely recommended, e.g. set the body on without bulb seal and mark interference with a Sharpie. I'd highly recommend not doing this on current new builds. At least not as the first step. Fit and mount the body with the bulb seal making sure to have it positioned exactly right, e.g. front/back and side/side. Only trim the aluminum if necessary. I've done three Roadster builds (1 Mk3 and 2 Mk4's) with little/no trimming required. In my experience, the aluminum parts, especially as currently delivered, fit quite well. Trimming should be the last resort once all other options are exhausted. Not the first.

I concur. The only trimming I find necessary these days is to the 3 nose aluminum panels and front splash panels.

Jeff

[j.miller]

I concur. The only trimming I find necessary these days is to the 3 nose aluminum panels and front splash panels.

Jeff

Yup but I must add one little thing... 1 out of ten cars I have to take .5in off the rear trunk extension to get a body to move forward where I like them... da Bat

[jrohrig]

Appreciate the info. Thanks