The Sterling Build Project blog 
Start 3/15/09 ===========>
Update 7/5/10

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The Sterling Build Project blog 

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Your kitcar body and chassis  ship out from our factory to you..... So where does it go from here you ask?  Follow the build in action.
Ready to be shipped to customer

After car arrives fit new wheels and tires or your choice.  (GM 5 lug 4.75)

Unpack the car and organize the parts and read your Sterling build manual.
Remove the body and off to the body shop

Now is a great time to clean up your classics chassis or use one supplied by us.

I put down a light grey primer over the black gel coat that's on the car. I do the block sanding with the grey so I can see the high and low spots. 
(The darker the color the more block sanding is needed)
I like to put the body up high to work on it
You can under coat the bottom with a sound proof coating
Now is a great time to make your own custom taillight designs.  We cut out 9" x 6" square openings to fit LED lights we found. (check back for progress)
Now is the time to fit the gas tank up under the rear body section. (very important to add tank before you set the body on the chassis.)
Dash designs are in the works
Final primer we used was PPG NCP271 block sanding primer.  I like how it goes on thick and wet sands easily.  
Set the body onto the chassis...
4/28/09
3/15/09 start date....
Three sides of the tank are bolted onto the 
special Sterling sub section at (6) locations. Please note tank must be raised up 3/4" or more to clear the chassis parts.

Next step is to attach the very large front underside nose section. Then the lower side sections.

Note: New rubber gasket between pan and body for a good seal.
5/5/09

To glue on my side and underside front panels I used body panel adhesive for fiberglass panels.  See your local autobody supply store. 

I used metal clamps to hold them in place until the seams were dry.

Note: I also use 1.5" wide tape for a clean edge. Then I peal it off just before all  the glue dries.

Off to the Import and Kitcar show at Carlisle PA 16th 17th   
Thanks to Turk I made it there....
Hinge the hood,  First I use a welding rod to locate the the point of rotation before adding in two hinge bolts.
 Now the reverse light, licence plate and frame, must be added.

5/13/09

5/8/09

5/10/09

6/10/09

Engine Cover

5/20/09

Hinges for top
New hood safety latch spring pin system
The top canopy opens and closes with a hydraulic system.  Hydraulic lines are run trough the car from the two lift cylinders in the cabin to the pump in the front trunk.
See the black lines below.

6/24/09

Our dash cover hides the gauge access holes.  See dash cover at our on-line shop 

gauges are now added. I used paper to represent the gauges so I could move them around to find the best location. 
I used tape to draw on the final gauge location.
7/19/09
Move e-brake lever back
Screw box in (4) Loc
7/5/09
7/12/09
Custom made seats just for the Sterling or other VW based Kitcars
Now the process of wiring the car

I test fit these tail lights as another option?

8/15/09 

Back from vacation, back to work 

7/28/09 

I just park the car and went on vacation. (to the beach) 
Great place for the fuse block because
we have our new dash cover to hide
everything. 
(part # UP-110) 
This is a great time to photo the underside.
< Rear Engine VW
< Front underside
Rear underside  >

8/9/09 

Now what paint color........ red...?  Race/Blue?....pearl/Yellow....?    metalic/White....? 

4-15-10

Sterling Sports Cars is a Registered Trademark of  Sterling Sports Cars LLC. 
Content and designs are Copyright protected

Three different Sterlings were photographed to make this step by step build page.     

3-22-10

 Paint shop now... First we take the car apart again and start with the block sanding process.

5-21-2010  Carlisle Kit Car and imports show

What color??  Silver ? , Blue ? ,or Red would be cool? Yellow ?   How about orange ?. (( stop back and see)) 
Its great building a car with all "new" parts from the body to the powder coated VW chassis, suspension parts, disk brakes, and body panels.
6-2-10 paint shop
block Sand..  block sand....  block Sand..... . and you get the idea....
Next,  we will be adding a new iPod sound system to the dash...