Mk5 Footbox Front Aluminum Installation -- Help!

[edwardb]

I'm likely going to display my ignorance here. Or that I'm just tired. Today I received the much anticipated anodized panels for my Mk5 30th anniversary build. The very first piece to install per the manual is the driver footbox front. It clearly requires some bending to get into place. But just how much? And in what sequence? I was torquing on it pretty good and still not in. Decided to stop and ask before going any further. Briefly looked at the passenger side and it's exactly the same situation. No mention in the build manual of anything special. I remember on the Coupe they talked about bending required to get the hatch floor in. If that's required for these pieces, a heads up with some suggestions might be in order.

Appreciate some words of wisdom from Mk5 builders that are past this point. Thanks in advance.

[michael everson]

I struggled with these as well. can't Rember exactly but I think I started with the panel 90 degrees to its mounting surface and rotated it into place. Nearly impossible to install without scratching the powder coating
Mike

[Higgybulin]

I had trouble as well. If I can remember, I got it positioned in the area with the left side of the panel closest to its final resting place, then pushed out from the inside near the middle and down and back at the top, all the while trying to turn the panel into its place. I thought it was just me !
Higgy

[Reddrig]

So the panels do need to be bent a lot in the foot box areas to get them in. The panels will snap back into place so don’t really worry about hurting the panels. Wear gloves it helps grip the panel and save your hands. The overlap was trial and error since it’s not really in the manual. This was the least enjoyable part of the build for me. Once you get them correct it makes since, it just takes some patience.

[rponfick]

Same issue. After many attempts, was able to get in without too much damage. I experimented with uncoated panel, but I see yours are already finished.
As I recall, I came in at an angle from the engine side, bottom first, bend, and then get the top to fit. Also, sequence of panels is fun as you are to install the engine side two pieces under the front panel. Outer footbox is way down the road.
Good Luck.
Ralph

[edwardb]

Thanks for the responses. Gave me some helpful hints and confirmed I wasn’t missing something too obvious. Getting a little rest helped too. There’s a lesson there… Got the driver’s side in and went ahead and put the passenger side in as well. Will be slightly inconvenient to drill, Cleco, bond, etc. with them in place. But I’m not taking them out again. Between the nice Anniversary powder coat and the anodized panels, not interested in any damage. Minimal if any so far. Here’s what worked for me on the driver’s side:

From the engine side, slide the panel in vertically and hook the bottom outside cutout over the outside 1-1/2” tube.

Rotate the top toward the outside and bend in the middle enough to clear under the upper 1-1/2” diagonal tube.

Once close, while still bending in the middle, an additional bend at the top toward the front to clear the top horizontal tube.

At that point, it drops into place and you realize it wasn’t so hard. The bends are relatively aggressive, but once in place the panel returns to flat.

The passenger side is the same only a mirror image obviously. This deserves a mention in the build manual IMO. Onward.

217374

[Jeff Kleiner]

Hmmm… Interesting. That panel is different on our Betas. The footbox outside turns and continues inward about 4” at the top under the square tube and then runs down to about an inch. The front panel follows this diagonal and rivets on top of it. I can understand the difficulty that you had with the full width front panel. The configuration may have changed when that square tube got relocated (we found that the Coyote wouldn’t fit with it where it was originally—-DOH!).

Jeff

[rponfick]

Hmmm… Interesting. That panel is different on our Betas. The footbox outside turns and continues inward about 4” at the top under the square tube and then runs down to about an inch. The front panel follows this diagonal and rivets on top of it. I can understand the difficulty that you had with the full width front panel. The configuration may have changed when that square tube got relocated (we found that the Coyote wouldn’t fit with it where it was originally—-DOH!).

Jeff

Jeff, with the black coating on all panels shown in the picture, I am not sure you can determine the configuration correctly. It would appear that the total front panel was one piece. My panels are as you described. I would think the front panel would be impossible to get in place if it were one piece. But I am often mistaken.
Ralph

[edwardb]

Jeff, with the black coating on all panels shown in the picture, I am not sure you can determine the configuration correctly. It would appear that the total front panel was one piece. My panels are as you described. I would think the front panel would be impossible to get in place if it were one piece. But I am often mistaken.
Ralph

The black panel on the front of my Mk5 driver's footbox pictured in post #6 is in fact one piece. Passenger side is the same. My first attempts to install indeed made me think impossible. But with bending and the sequence I described, encouraged by the responses I received, they go in.

[rponfick]

The black panel on the front of my Mk5 driver's footbox pictured in post #6 is in fact one piece. Passenger side is the same. My first attempts to install indeed made me think impossible. But with bending and the sequence I described, encouraged by the responses I received, they go in.

Well, I am certainly glad I got the edition with easy install 2 piece front panel version. Is your Mk5 a very early edition? Mine is serial No. F5R1011225M5, completion date 3-15-25.
I wonder when and why they changed, or if it had something to do with the 30th Edition.
Ralph

[edwardb]

Well, I am certainly glad I got the edition with easy install 2 piece front panel version. Is your Mk5 a very early edition? Mine is serial No. F5R1011225M5, completion date 3-15-25.
I wonder when and why they changed, or if it had something to do with the 30th Edition.
Ralph

I'm F5R1011258M5, completion date 06/14/2025. #14 of 30 Anniversary Mk5's. So later than yours. I doubt it has anything to with 30th versions. Probably just a running change. But I don't have any way to know that for sure. It's really not a big deal once you expect it (vs. I'm doing something very wrong...) and have an idea how to proceed. Forum to the rescue.