Mounting a roof on an uneven surface can result in an improperly mounted body. By locating the roof using one central locating point (both front and rear), you can be assured that the body will be mounted properly on the chassis.

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HINGES FOR DECK LID?

I am having a problem figuring out the best way to hinge the deck lid on my Pontiac Grand Prix. Could you give me some suggestions? I tried to use a piano hinge, but it held the center of the deck up, which did not leave a smooth finish for air flow.

Since the deck lid has a crown from side to side, the only real solution for making an accessible deck lid is to use our Deck Lid Hold- Down Kit. This kit includes an aluminum hold-down channel, aluminum pins, scuff pads, flip-up steel clips and 2 pre-welded nut/gusset assemblies. 

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Deck lid puckers up in the middle when installed. What causes this, and is there anything I can do to fix it?

When mounting the quarter panels to the bumper cover, unless the alignment is exact, the deck lid opening may be a little smaller than the deck lid. Due to tight tolerance, this is a common problem. Two solutions would be:

1. Make sure that the end of the quarter panel is exactly in line with the deck lid indentations in the bumper cover. If it is off even slightly, the deck lid will not fit properly.

2. If the quarter panels are already riveted to the bumper cover, the preferred solution is to flatten out one flange of the deck lid and re-break (bend) the flange to make the deck lid slightly narrower.

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TEMPLATE ALIGNMENT

Please explain the locations of the straight-up centerline template and side to side template with regard to the notches in the template and location front to back.

The notches that are on the centerline template are at the intersection of the windows and the body panels such as the windshield/roof intersection. The side to side template is placed on the trailing edge of the roof immediately in front of the rear window. Place a square on the roof along the centerline on the front side of the side to side template. This will insure that the template is 90 degrees to the curve of the roof which is the proper angle as specified by NASCAR. 

What type of rear window braces do you recommended for your short track bodies?

Many racers are using 3/4" aluminum angle. You can put a curve in it in the vise and put a slight bend every 2 or 3 inches until you have it formed to the outside of the rear window. Then you can cut it to length and attach it through the window ledge at the top and bottom with screws or rivets as required by the rules. We also recommend that you build a support from that brace down to your interior panel and from the bottom of the interior panel down to the chassis to prevent any flex.

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I recently mounted my Five Star body and began to scuff up the outside of it and I noticed that it is hard to scuff. Am I suppose to scuff your bodies before applying the sealer and paint or is it already prepared and all I need to do is apply sealer and paint?

You must scuff all panels before painting to insure proper paint adhesion. As you have found, the gelcoat surface on the fiberglass panels is harder than normal paint so it will require some extra effort. We use 3M scotch brite pads part # 07447 (red). You should scuff the panels until the entire surface is dull. You will see that it is easier to scuff the aluminum panels. It is also important to use a quality wax and grease remover to insure that there is no wax residue remaining on your parts. 

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The foundation to mounting a stock car body is the roof. Be sure to take time to mount the roof properly. If you are off here, it will affect many other dimensions critical to meeting a template and obtaining maximum performance from your body. The single most critical roof dimension is the Highest Roof Point (back from the windshield) which is Dimension "N" on your Guideline Chart (chart below). This dimension will set up the roof with the proper contour which all the other panels mount from. However, some series (namely NASCAR) specify the highest point to be ten inches back from the windshield. While you can still meet the template, the other body panel dimensions will off accordingly. 

If your association requires a 47 inch roof height and a 4 inch nose height (i.e. NASCAR Slim Jim All-Pro Series), simply lower the "I" and "J" Dimension one-half inch below that specified in your Guideline Chart.

I know the fiberglass fenders have an internal flange that matches the plastic nose. But how do aluminum and steel fenders mount when there is no flange?

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DOOR OVERLAP?

All Five Star bodies are designed so that the doors overlap both the fenders and quarter panels. The roll radius made into the door is larger and therefore follows the contour of the fender and quarter panel. 

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A-POST MOUNTING?

All the new body styles now incorporate an A-Post pad which makes installation as simple as lining up the front of the door with the leading edge of the A-post. To fit the fender, you will need to cut out a small portion of the fiberglass pad to allow fender clearance (see illustration below). 

PAINT ADHESION?

All Five Star plastic noses and bumper covers are made from high impact polypropylene plastic and require a primer in order for paint to adhere. For best results, use only Five Star Plastic Primer, which is specially formulated for polypropylene plastic. Be sure to follow the instructions on the can.

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CUTTING LEXAN

Use a saber or jig saw with a medium to coarse tooth blade running at slow to medium speed. To avoid stress risers which will cause fracturing, be sure to sand the edges smooth. Also, when installing the window, make sure that the hole in the Lexan is slightly larger than the fastener to avoid excessive stress in this area.

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