Body Installation

[jimwallace]

I had some sons and friends help me install the body today (Mk4) and I started to put the rear bolts in that secure the body to the frame. I can't get to the back side of the frame plates that these bolts go thru to get a nut on them due to the gas tank. The FF manual shows installing the body on a frame with no gas tank or trunk floor in, but I've got the chassis finished. Am I missing something? Does the gas tank have to be removed in order to get the nuts on these bolts? If so, it would have been nice to mention this in the manual. Thanks for any advice you can give.

[emac]

Yes the tank needs to be lowered. I just put a floor jack under it and removed the bolts at the rear of the strap and just lowered it enough to get the bolts in. Yes, its a pain, but after the second or third time it gets pretty easy!

[cwrandolph]

I don't have a Mk4 but on my Mk3 I used all-thread instead of a bolt. The all-thread can be inserted through the body and into a nut next to the gas tank. It's a little tight but probably easier than dropping the tank every time.

[JKleiner]

The RH side of a Mk3 is a pain however with the lowered structure for the non-perky butt on the Mk4 it's all but impossible.

My solution was was to use 1/2" long 7/16-14 bolts from the tank side threaded into coupler nuts:



There are no sleeves on the inside. Instead I used all thread. After putting it thru the body but before threading it into the coupler I put a fender washer then a nut on it---the washer winds up against the inside of the body and the nut is between it and the coupler. After the all thread was snugged into the coupler the "floating" nuts and washers were used in conjunction with the sleeves on the outside to adjust the rear valance in or out as needed to meet the lower edge of the trunk lid. Afterwards with it positioned and locked down I cut off the excess all thread and installed the quick jacks with chrome acorn nuts & chrome washers. Although you really had to stick your head inside to see it the coupler nut plus a couple of inches of all thread remained visible:



I simply covered the whole works with a piece of wire harness split loom:



Nothing fancy, just hardware store all thread, couplers, nuts & washers. Simple---cheap---easy

Cheers,
Jeff

[PhoneGuy]

I have a MK4 and I used the same hardware as Jeff (1/2" long 7/16-14 with threaded couplers & washers) and I was able to do what he suggests without lowering the tank. What I did that was different is I used 2 pen magnets and slid 1 pen magnet through the hole of the chassis and then held the 7/16 bolt with both magnets (1 on the head and tail end) and within 15 minutes I had a bolt and threaded coupler through my chassis waiting for the body. I know it sounds complicated, but it turned out to be fairly easy and best of all I didn't have to lower the tank. One thing that I did have to do is I had to loosen the PS tank bolt that is towards the front of the car so that I coule squeeze a 7/16 bolt thru for the lower PS side as this was the only one that was "difficult" but still did not have to lower the tank.

Good luck, Bob

[MPTech]

x2 what Jeff said.

the Mk4 it's all but impossible.

My solution was was to use 1/2" long 7/16-14 bolts from the tank side threaded into coupler nuts:

I reluctantly dropped the tank and installed them. Just do it and get it over with.