Rusis MK4 Roadster Build Thread

Hi guys,
Today I went to go pick up my MK4 from the factory. My Dad and I are going to be building it with the help of my brother and cousin. I am excited to get started on the process of building the kit. When doing the parts check, should I go through bolt by bolt or just check off the bigger parts? I am sure more questions will come up as I start the build.

My build:

MK 4 complete kit
Powdercoating roadster chassis
302-351 engine/trans mount kit
31 spline 11.25" driveshaft
Body cut-outs
Box 9d low back vintage race seats
Power steering components w/ complete kit
3 link deluxe rear suspension
15x8/9 lug halibrand replica wheels
Wind wings
Sun visors
MK 4 Chrome roll bar passenger and driver
Side louvers
Center dash supports
Performance 11.65" rear brake set

Attachment 124459Attachment 124461

Every bolt.
It will save you from getting held up later on and it’s good to know all of the parts up front.

Every bolt. And get something like these to make sure

https://www.amazon.com/Pit-Posse-PP2...e%2C214&sr=1-3

https://www.amazon.com/Dorman-415-10...e%2C214&sr=1-7

Good tips on the thread gauges!

- Make copies of your POL lists, and tape the appropriate sheet to the box. It'll save a lot of time looking for things, and you can scratch off what's not in the box anymore.
- Save several lengths of the packing paper sheets. They're great for wrapping/protecting the aluminum panels, and making templates.
- A couple of "Paint Pens". Put a daub of paint on each bolt/nut that's been final torqued or tightened.
- A couple of "High-Lighter" pens and a pack of the "Sign Here" type of paperwork flags. Draw a line through each assembly step if it's completed, or flag the page if you have to go back.
- Another inexpensive but very valuable tool - Deburring Tool The edges of the panels can be sharp.

Congratulations and thanks for posting. I look forward to following along with your build. Sounds like you have a good group helping you. I know you are going to have a blast.
-Steve

Thanks for the advice and I will make sure to keep the project as organized as possible. Today after doing the parts inventory, I want to start working on the disassembly of the body but I haven't finished my body buck yet. Is the body fine for a day or two without being on a buck or should I place it back on the frame after I am done working?

Quote:

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Originally Posted by Rusis

Thanks for the advice and I will make sure to keep the project as organized as possible. Today after doing the parts inventory, I want to start working on the disassembly of the body but I haven't finished my body buck yet. Is the body fine for a day or two without being on a buck or should I place it back on the frame after I am done working?

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It will be fine, set it on the floor, in the yard, where ever. A day or two is not going to hurt it. I've heard of people leaving it in their back yard for years... Welcome to the fun. 2x the inventory part. I recommend keeping everything in the original box and as POL items come in, put them in the box they were originally supposed to be in if possible.

This forum is a wealth of knowledge...

FYI, when you can, update your signature line with some info about your build. Ie. Engine, suspension info, etc. It will help others help you...

And most of all... HAVE FUN...

Can't agree more on doing the inventory and keeping things organized. One mistake I made was not realizing that sometimes there are parts in a bag inside another bag. A few of them weren't marked as such and I concluded I was missing parts as I went through the inventory.

Enjoy the build, it's actually a lot of fun!

Where are you located?

If you have to stack the boxes on top of one another to save time, as you are doing inventory write the main parts inside and the bag numbers on the side of the box with a sharpie so you can see it when stacked. This saved me a lot of searching and unstacking.

Something I started about 4 months in that I wish I had started out with is keeping a small ring bound book for notes. There will constantly be things to remember to do later and you should keep it all in one place (ie. torque this or that bolt, etc)

Agree on the thread checker, I constantly use this.

Try to look ahead and be prepared for the next step but at the same time don’t buy things too prematurely , ie—> battery/tires.

Every hour spent reading other build logs will save you time but cost you 2x in upgrades!

Welcome and enjoy the process.

Great thanks for the help. I will, but I think I have to have ten posts before I can update my signature. I will make sure to do my research. Does anyone have a digital spreadsheet of the parts list to be able to look up parts? I know not all the parts are the same, but it would help. I am located on the North Shore of Boston.

I have put together the upper and lower control arms on both sides and have installed all of the brakes disks and calipers. Tomorrow I will be installing the rear axle along with the pedal box. I will post pictures later on the progress I have made so far. I am going for a classic look on the car and am wondering what company makes good radial retro style good year eagle tires and what size I would need for 15 in halibrand replica wheels?