Unpack and Inventory

Unpack and Inventory

Chassis setup

place FFR body/chassis shipping assembly on four jack stands (or dollies) 38

Chassis is 28” wide to the outside edge of the main tubes. Two Harbor Freight or Home Depot furniture dollies can support the chassis/body assembly. When transporting in an auto trailer (like those rented by UHaul), use four old tires resting on wooden shipping pallets to support the chassis above the trailer tire rails (the typical trailer is about 75-78” wide and the gap between rails is about 35-40”).

remove all duct tape from the body and clean any residue off with acetone
notch 40x2x4 lumber at approximately 35” (measure precise span across the cockpit midpoint) for a body brace to prevent fiberglass stressing under the doors when body is moved; some give in the brace is necessary to allow enough flex to remove the body

Inventory

inventory all parts and reconcile to shipping bill of lading
check condition of all items, specially finished pieces like the windshield
review vendor backorder list
add any missing items to the backorder list and notify vendors of any damaged or missing parts

Label contents on FFR\Breeze shipping boxes, and keep a copy of the physical inventory list with box locations. Maintain a record of back-ordered parts. Re-bag and label loose parts.

After all items have been delivered, FFR will officially close out the order and generate a Manufacturer Certificate of Origin (MSO). Verify that the serial number on the chassis frame and the number on the MSO are identical. A mismatch will complicate vehicle registration (for additional information, see Vehicle Identification).

On the Mk3.1, the chassis number is located on the square 2×2 chassis brace located near the driver's left knee (and to the left of steering wheel). While the chassis number is stamped on bare metal, it may be covered by powder coating. If so, light sanding will reveal it. FFR does not stamp the chassis number anywhere else on the frame.

Remove body parts

Remove the connecting bolts from the door hinge and carefully pull off door

Do not attempt to open the doors since the rough body trim does not permit normal hinge function. Wear gloves or use shop towels when handling the fiberglass body; unfinished fiberglass has sharp “needles” that can easily cut unprotected hands.

remove connecting bolts from door hinge and carefully pull off doors
dismantle trunk hinges, including angle bracket that attaches to chassis
carefully lift off trunk
remove the hood (for shipping, held in place with duct tape)

Store all removed parts — door nuts, washers, and trunk hinge assemblies — in plastic baggies with labels that indicate part number and location.

Keep fiberglass body parts in a safe area, away from rough surfaces. If possible, the doors should be stored away from moisture since they have metal parts.