How to fit an "X Pack"...
Having fitted 2 different "X pack" kits, I thought I'd show you how we did it... Starting at the rear... With the bumpers, side mouldings and rear window trims removed, (rear window trims removed only for MK3 kit), prepare the rear arches to accept the wider wheels.
This can be done in many ways, but the easiest way is to separate the inner and outer arches and cut into strips that can be bent into a
horizontal position and welded or rivetted back together. This forms a neat and easy to cover inner arch. Make sure that the cut "strips" are high enough
to accomodate the wider wheels over the full suspension travel. I used the existing swage line as a guide. If the wheel arch is rotten then it is easier to
remove the entire outer arch and fabricate a new piece to form the new inner.
Trial fit the rear arches and trim back the new inner arch as required so that it doesn't quite touch the x pack arch. Any gaps can be taken
up when the arches are fully fitted, by joining the inner and outer with fibreglass matting and resin to fully seal the arches.
Prepare the panel surface around the edges (where the "x pack" arch touches the metalwork), to accept the fibreglass matting and resin by sanding through the paint to bare metal.
At this point lots of holes can be drilled in these areas to allow the resin to pass through and form many "rivets" to add strength
to the joint. I didn't do this, and have had no problems... but it sounds like a good idea. Cut the matting into strips and follow the
instructions for applying the resin and bond to the prepared areas (everywhere the new arch contacts the shell). Work quickly and fit the
arch in position and rivet/screw in place. These temporary fixings can be removed when the resin has cured as they may protrude through the filler and spoil
the paintwork... been there, made that mistake, got the T shirt...
Front Arches There are 2 options for the front arches when fitting the MK3 kit... you can either buy a kit to fit to the original steel wings or complete wings. For the MK2 kit there is obviously only the first option.
For the MK2 kit and MK3 where the steel wings are retained, a similar approach to the rear arches can be used. Some people cut a huge amount of steel away, but I have found that that the way shown below
means less work to seal the new arches underneath.
For the "full wing" MK3 kit, remove the entire front wing and prepare all the mounting flanges for bonding the fibreglass in place. I found that the front panel needed modifying around the air vents...
this should be bent back to form a flange to bond to. The photo below just shows the wing cutting into the front panel, (at the bottom). It is important to keep trial fitting the wings as they will need slight adjustment to get them to fit exactly (flanges etc).
Once you are happy with the fit, fibreglass the wing into place. Secure the panel as you did for the rear arch with rivetts or screws until the resin has hardened... these can then be removed if desired. I left a couple in along the flange in the engine bay for
peace of mind.
Once all the fibreglassing has been done and the arches are secure, the edges can be blended into the bodywork.
Important: use a flexible body filler as the joints are liable to crack.
Another useful trick is to lay some fibreglass matting over the edges of the panels to help secure them further to the shell and prevent cracking later. Be careful not to drip too much resin down the panel as it is extremely difficult to remove.
Our MK2 kit fitted to a MK3 car before blending of panels and fitting of front spoiler. Note: the side skirts are not part of the original kit.
