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post #130 of (permalink) Old 04-27-2018, 04:16 AM Thread Starter
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Join Date: Sep 2009
Location: Lake Orion, MI
Posts: 5,718

Busy week so not as much shop time. With warmer weather comes yard work. But did manage to get the glovebox mostly fabricated. I used very similar materials and methods as #8674, the same depth, but a different shape. I made three internal forms out of leftover shelf stock MDF bolted together with spacers between, a back out of .040 aluminum, and a front ring out of .090 aluminum. The sides are galvanized steel duct material from Home Depot. First wrapped the sides around the forms with about a 2-inch lap at the top held for now with JB Weld. Then a bunch of pie cuts and bent over onto the back. Then more pie cuts and bent around the front ring. Right now the back and front ring are also held together at the bends with JB Weld. Once it’s installed, the front ring will be bolted through the dash, and the lap on the top will have bolts from the latch. The back isn't going anywhere. Once it was done, wasn’t too easy to get the forms out. Ended up drilling holes in them and they broke pretty easily.

Then made the cutout in the dash, drilled mounting holes, and temporarily bolted into place. Still need to countersink the screws into the face of the dash. They’ll be buried under the dash covering. The glovebox will be removed while the covering is applied, with the covered wrapped through the opening and glued onto the back of the dash. The interior of the glovebox will also be covered, and that wrapped onto the front lip. Then bolted in placed with a nice finished transition when open. The door will be two pieces of .040 aluminum wrapped with covering and sandwiched together. I’m using the same 173167 Richelieu cabinet hinges from Lowes as #8674, which were also on #7750 from Alex’s Custom Roadster. Their a little chunky, but work very well and have the perfect geometry to lift and drop the zero clearance door out of the opening. I looked at a couple other possibilities but came back to those. Also using the same VW 111857131L pull/lock as #8674. Read about that one on the forum quite some time ago, and it’s also perfect for this application. Available lots of places. This one was $20 shipped from eBay.

Here is the mostly finished glovebox installed in the dash.

In the chassis with a very temporarily mounted door half. When finally fitted and covered, the door will be completely flush with the face of the dash.

Interior checking the operation of the hinges, mounted temporarily with double back tape. As mentioned before, the mounting screws still need to be countersunk. I used maybe more screws than necessary. But once I had the hole cut, took a pretty big divot out of the dash and it was a little floppy. So using enough screws so that the glovebox puts some strength back into it. Feels solid.

This is the VW latch that will be installed in the door. I like it because the latch is spring loaded and is just push to close. To open, press the button and pull. The lock is only needed if you actually want to lock it. Some other latches require the key all the time. This one doesn’t.

I saw this in the shop while making the glovebox, and got a chuckle. I seem to be in the upper range of the “how many clecos does it take” contest. What about a new category? How many clamps does it take? This is gluing the front ring on the glovebox after bending the metal over onto it. The scrap piece of MDF is to make sure it ends up flat. Maybe I got a little carried away.

Most of the remaining work on the glovebox will be when it’s covered and then fitted for final assembly. Next up is the center switch console. With that fabricated, my dash will be nearing completion and ready for covering.

My Gen 3 Coupe update box arrived this week from Factory Five. Contained several updated aluminum panels, one pair of new aluminum panels, and updated hinges for the hatch. The good news is none of the panels that I’ve drilled and fit were included. Which is what I expected based on some advance information. One of the pieces was mounted for shipping. But the rest were from the loose aluminum box. The four pieces are: (1) Replacement front wheel rear lower splash. New pieces are quite different. (2) Replacement upper engine bay splash guards. The ones that are mounted inside the nose. Only minor changes. (3) New pieces, not received before, to mount in the front of the rear wheel well. Covers several openings in that area. (4) Replacement front wheel inside splash panels. These are the ones that were previously mounted. No big deal. In this picture the old piece is still mounted and the new piece below. The main difference is opening up the area where the headers exit. I’ve seen this mentioned in other builds where guys have cut the piece above the opening off. Now it's official I guess.

The revised hatch hinges apparently allow it to open further. I did have the old ones powder coated already. Oh well. Will include the new ones in my next batch. Thanks Factory Five for making continued improvements to the Gen 3 Coupe and supplying the updated parts to those of us who’ve already taken delivery. My understanding is they shipped 60 or so of these update boxes.

Big shoutout to my buddies at the 2018 Huntington Beach Cruise-In this weekend! Some day I’ll have to make it out to that event. I grew up not too far from there. This weekend we have a big Cars and Coffee to kick off the season. This one typically has 1000+ cars and is pretty crazy. Ford Performance is one of the features of this months event. Weather looks cool but so far dry. Looking forward to getting out.

Build 1: Mk3 #5125. Sold 11/08/2014.
Build 2: Mk4 Roadster #7750. Sold 04/10/2017.
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Build 3: Mk4 Roadster 20th Anniversary #8674. 03 of 20. 2015 crate Coyote, 2015 IRS. Legal 04/18/2017.
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Build 4: Gen 3 Type 65 Coupe #59. Gen 3 crate Coyote. Delivered 12/2/2017.
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Last edited by edwardb; 04-27-2018 at 11:20 AM.
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