MPTech: Building my Factory Five Roadster

Back from vacation in Cancun and back to drilling. I've been piecing together and painting the disc brake calipers. Mounted the fronts, working on the rears. Meanwhile,
[SIZE="5"][B]Big THANKS [/B][/SIZE]to Rich for helping me turn my big sheets of aluminum into smaller bent pieces. :D

Also [B][SIZE="5"]Thanks[/SIZE][/B] to Don Payne for a great template!!

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

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).
[IMG]http://i9.photobucket.com/albums/a78/MPTech/IMG_0102.jpg[/IMG]

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

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

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

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

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

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


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.