Factory Five Racing Mk4 Roadster Assembly Manual

Text of Factory Five Racing Mk4 Roadster User Guide:

• Factory Five Racing Mk4 Roadster, 456 www.factoryfive.com 508-291-3443 Final Body Mounting Fit the body back on the chassis. Be very careful with the sides and slowly work it down into position. Pull the sides out around the chassis and make sure the body covers the rear cockpit wall and top of he dash without pulling the material off either. Quick Jack Mounting Re-mount the body in the rear with the quick jacks.

• Factory Five Racing Mk4 Roadster, 300 www.factoryfive.com 508-291-3443 Locate the horns on the upper radiator down tube and drill a 3 / 16 ” mounting hole. Attach the two horns to the radiator down tubes using a supplied #14 screw. Then drill a second 3 / 16 ” hole so the horns will not rotate.

• Factory Five Racing Mk4 Roadster, 361 www.factoryfive.com 508-291-3443 Trunk Hinge  ½” wrench, 3 / 16 ” hex key  Trunk hinge components. Press the bushings into the hinge arms from either side. Use the carriage bolts and 5 / 16 ” locknuts to bolt the mounting pads to the arms leaving them just snug so they can be moved without loosening the bolts.

• Factory Five Racing Mk4 Roadster, 321 www.factoryfive.com 508-291-3443 The push-on weather strip goes across the top of the trunk walls and rear floor. Mounting the Body Rear Quick Jacks  ⅝” wrench, ⅝” socket, ratchet  Quick jack bumper components  The main locating points for the body are the rear quick jack mounts; these will set the body in the correct position front to back as well as locating the rear half up and down and side to side.  When bolting the body down the first time to do the fitment you can leave the quick jacks off and only use the hardware, this ma

• 177 www.factoryfive.com 508-291-3443 Drill a ¼” hole through the tank flange on the mark made. Use the ¼”bolt and locknut to attach the retainer to the tank. Fuel tank install At the locations on the tank where the tank straps come near the tank, use a pair of pliers and bend the bent parts flat.

• 106 www.factoryfive.com 508-291-3443 The coil-over hats have a snap ring which holds it in place. Remove this snap ring to assemble the coil over shock. Slide the rubber bumper about two inches down on the shaft. Put the spring and hat on the shock and rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the s

• Factory Five Racing Mk4 Roadster, 387 www.factoryfive.com 508-291-3443 Cut out the headlight templates from the back of the manual on the outermost diameter and tape them in the center of the fender with the line level with the ground. Cut the center of the template out and trace the inner circle with a marker.

• Factory Five Racing Mk4 Roadster, 422 www.factoryfive.com 508-291-3443 Carpet  Razor knife, silicone, caulking gun, spray glue, brake cleaner or acetone.  Interior trim/carpet  The adhesive used to hold the carpet down is the same as we used on the dash pad. 3M ® Super77™ or Super90™ work best. Wipe down the bare aluminum with acetone or brake cleaner for good adhesion.

• Factory Five Racing Mk4 Roadster, 344 www.factoryfive.com 508-291-3443 The four remaining screws are used to hold these brackets in place. They can either be countersunk into the body or used to hold down the hood bumpers to hide them completely. Attach the cam wedge to the underside of the hood handles and adjust for tightness using a 2.5mm hex key. Hood Scoop  Drill, 3 / 16 ” drill bit, marker, ruler, tape measure.

• Factory Five Racing Mk4 Roadster, 200 www.factoryfive.com 508-291-3443 Use a long 60” brake line and route from the 5 / 8 ” master cylinder out the front and down the front of the footbox. From the front of the footbox angle into the 4” main tube under where the footbox floor would be.

• Factory Five Racing Mk4 Roadster, 36 www.factoryfive.com 508-291-3443 Tighten the balljoint using the arm for leverage with a Vice holding the ball joint. Screw the grease fittings in to the ball joints and tighten with a ⅜” wrench.

• Factory Five Racing Mk4 Roadster, 375 www.factoryfive.com 508-291-3443 Locate the template in the appendix and only cut out around the outside diameter of the circle. Tape the circle in the gas cap recess of the body. Use a 3½” hole saw for the center opening. If you do not have a hole saw this size, you can cut the center circle out of the template and use the remaining template to mark for a jig-saw instead.

• Factory Five Racing Mk4 Roadster, 414 www.factoryfive.com 508-291-3443 Radiator Aluminum  Drill, ¼” Nut driver, ⅛”, 3/16” drill bits, rivet tool, floor jack, marker, ruler, silicone, caulk gun.  Secondary body fasteners, engine bay aluminum.  Use care when handling aluminum, the edges are sharp and can cut you. The radiator and its plumbing were installed before the body was mounted. The radiator is being held up at the bottom by a couple of zip ties through a quick jack bumper hole. Use a floor jack under the radiator to hold it in place. Cut and remove the zip ties. Mark the radiator floor piece for either screws or, rivets for a cl

• Factory Five Racing Mk4 Roadster, 389 www.factoryfive.com 508-291-3443 Test fit the light bucket and rubber gasket making sure that they sit flat and the bucket is centered on the fender. Mark and drill the four mounting screws for the headlight bucket using a 1 / 8 ” drill bit. Side louver  Drill, 1¼” hole saw, jig saw or air saw, measuring tape, marker  Side louver template

• Factory Five Racing Mk4 Roadster, 355 www.factoryfive.com 508-291-3443 Hold or tape the door in position and attach the hinge to the studs. Adjust the door with the hinge until the panel surfaces are lined up with the body. Start at the top of the door and match the curved surfaces.

More Instructions:

	Factory Five Racing Mk4 Roadster Assembly manual 12-11-2023 553	DOWNLOAD
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	Factory Five Racing Mk4 Roadster Assembly manual 19-05-2023 551	DOWNLOAD

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