Tim Melena
New Member
I am looking for your suggestions on the most efficient order to conduct the reassembly once all body work and painting is completed.
Reassembly question
- Thread starter Tim Melena
- Start date
Malc
Well-Known Member
I will assume you have a completely bare shell.
I would suggest the following which is basically how they are put together in a factory. Use your common sense and take your time. Suggest you test the electrical harness as you put it in and as you connect it up.
1.. Install wiring harness, front and rear lights, wiper motor assembly
2.. Install brake and fuel lines, fuel pump and tank.
3.. Install belt trim, C pillar emblems
4.. Engine, gearbox, propshaft, rear axle, front and rear suspension, radiator, brakes, exhaust (don't forget the speedometer cable)
5.. Glue in roof foam lining
6.. Glue various pillar trim pieces and window surrounds.
7.. Install Headlining.
8.. Install interior sound deadening.
9.. Install Front interior carpet
10. Install heater assembly.
11. pedal box and handbrake
12. dashboard, steering column, centre console
13. Rear side windows with seals and trim
14. Rear shelf trim and window
15. Boot (trunk) seal
16. Boot trim
17. Door seals
18. rest of carpet, seat belts, seats
19. Windscreen
20. Doors, bonnet and boot lid.
21. trim (front grilles badges etc)
That should keep you amused for a while!
I would suggest the following which is basically how they are put together in a factory. Use your common sense and take your time. Suggest you test the electrical harness as you put it in and as you connect it up.
1.. Install wiring harness, front and rear lights, wiper motor assembly
2.. Install brake and fuel lines, fuel pump and tank.
3.. Install belt trim, C pillar emblems
4.. Engine, gearbox, propshaft, rear axle, front and rear suspension, radiator, brakes, exhaust (don't forget the speedometer cable)
5.. Glue in roof foam lining
6.. Glue various pillar trim pieces and window surrounds.
7.. Install Headlining.
8.. Install interior sound deadening.
9.. Install Front interior carpet
10. Install heater assembly.
11. pedal box and handbrake
12. dashboard, steering column, centre console
13. Rear side windows with seals and trim
14. Rear shelf trim and window
15. Boot (trunk) seal
16. Boot trim
17. Door seals
18. rest of carpet, seat belts, seats
19. Windscreen
20. Doors, bonnet and boot lid.
21. trim (front grilles badges etc)
That should keep you amused for a while!
Tim Melena
New Member
Thank you oh wise one!
Yes a good list!! where was it when I did my recent reassembly.
C-pillar roundels, door locks/handles and waste trim before side windows and interior!!
I had to take my doors & interior apart a few different times learning the 'proper sequence'
enjoy the reassembly!
-shanon
C-pillar roundels, door locks/handles and waste trim before side windows and interior!!
I had to take my doors & interior apart a few different times learning the 'proper sequence'
enjoy the reassembly!
-shanon
blumax
(deceased)
Re-assembly--word of caution
when reinstalling belt trim--give the fresh paint some time to cure beyond the paint shop. Then when the time comes to install bolt on moulding--
CAUTION---DO NOT OVERTIGHTEN THE NUTS--securing same in place--do tighten barely more than than finger tight--these karmann bodies are very flexible and if nuts are too tight the sharp edges of the trim pieces will cut into the paint in the quarter panel area and possibly on the doors.
Speaking from experience!!
when reinstalling belt trim--give the fresh paint some time to cure beyond the paint shop. Then when the time comes to install bolt on moulding--
CAUTION---DO NOT OVERTIGHTEN THE NUTS--securing same in place--do tighten barely more than than finger tight--these karmann bodies are very flexible and if nuts are too tight the sharp edges of the trim pieces will cut into the paint in the quarter panel area and possibly on the doors.
Speaking from experience!!