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PHASE III--CHASSIS
CONTů

  • SUSPENSION/STEERING- Front and rear suspension parts, steering column and linkage should be installed first. The goal is to get a running chassis before attaching the body.
  • BRAKE/CLUTCH- Pedal location and installation is first. Location for the master cylinders for both are next. The running of the clutch and brake lines should be done AFTER the installation of the power train. Brake and clutch lines can be re-routed easier than re-locating engine mounts.
  • DRIVE TRAIN- The engine/ transmission and drive line is next.
  • BRAKE/CLUTCH LINES-These lines can now be installed. Also, location of any slave cylinders will be addressed at this time.
  • COOLING SYSTEM- Radiator (s), mounting brackets, as well as transmission lines and A/C condenser and related lines may now be installed. Surge tanks, cooling fans, shrouds and any recovery systems should be addressed at this time.
  • HEATING AND A/C- Your heating and A/C unit should also be installed. Note: Depending on your configuration, you may have to address the heater core location as well as check for clearance in engine compartment for the A/C compressor during the DRIVE TRAIN installation.
  • ELECTRICAL- The electrical system may now be tended to. Placement of the fuse panel and the routing of the harness may now begin. HINTů Electrical conduit can be welded or fiber glassed into hard to reach areas such as under door sills and pull wire placed in it to allow you to pull the wires through the conduit at a later date when access to these     areas become difficult or impossible to reach. As a bonus, the conduit hides the wiring making for a cleaner installation.
  • FUEL SYSTEM- Fuel tanks/cells may now be installed and appropriate lines ran.
  • EXHAUST SYSTEM- Routing of the exhaust system can be done now or when the body is mounted to insure proper clearances. Depending on the kit you are building, this step may have to wait until the body is mounted. Examples of this would be a Cobra or a Cord kit where the exhaust exists the vehicle through opening in the body and placement is  crucial.
  • WHEELS/TIRES- This may seem pre-mature, but to insure you have adaquate clearance in the fender wells and the vehicle will "SIT" properly, it is recommended that this decision be made now.
EDITORS NOTE:
At this stage of assembly, you should have a running, rolling chassis. If, for any reason, you don't, it is strongly suggested that any additional work required to complete your rolling chassis be done and that all the chassis components are tested and operational before the body is installed.

PHASE IV
BODY

  • INITIAL FIT- Check for proper clearances and tab mounting positions. Once the body shell has been properly aligned and attached only then should the doors,deck lids, bumpers and glass be fit. Fiber glass is very flexible and can make fitting large parts difficult if you don't have solid, rigid attachment and latching points.
  • BODY WORK- Once the shell has been permanently attached, body prep can begin.
  • INTERIOR- Rough fitting of the interior can also begin at the same time the body work is progressing. However, it is strongly recommended that the finished upholstered interior not be done until AFTER all painting has been completed.
  • FINAL FIT- Once all basic body work has been completed the final fit for all parts can be done. Once this is completed painting can commence.
  • FINAL ASSEMBLY- After all parts have been painted final assembly can begin.
  • UPHOLSTERY- Once doors and lids have been installed the upholstery can be done.
  • FINAL WIRING- Interior wiring and installation of gauges, stereo, television, and any other electronic components may be done.
  • GLASS- The glass can now be installed.
  • EXTERIOR- The bumpers, lights, windshield wipers, weather seals, and medallions can be installed.

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