HPA Motorsports Inc. 604-888-7274 www.hpamotorsport.com CLUB-SPORT ROLL BAR: Volkswagen Mk4 Golf Congratulations on the purchase of your Club-Sport Roll Bar from HPA Motorsports! The engineering elements used in HPA s custom built roll cages are now available for your high performance street use in the form of this bolt-in four point roll-bar. Offering increased on-track safety and added chassis rigidity, it features a removable harness bar and maintains full functionality of front and rear seats. Note to Racers: This product may not conform to the regulations of your local sanctioning body. Please refer to your rule book for clarification. Approximate Installation Time: 12 Hours Skill Level: Intermediate Requires precision measuring, cutting and finishing work. No welding required. This Installation Requires Two Persons 13mm Socket 17mm Socket 13mm Wrench 17mm Wrench 5mm Allen Key 10mm Allen Key Ratchet Extension Torque Wrench Pliers Paint Marker Center Punch Scribe or Pick TOOLS / SUPPLIES REQUIRED: Utility Knife Flashlight Magnetic Holding Tool Power Drill 1/8 Drill Bit 11/32 Drill Bit 3/16 Drill Bit 2-1/4 Hole Saw De-burring Tool Philips Head Screwdriver Contact Cement/Spray Glue Heat Gun (or hairdryer) Grease Torque Specs: The recommended torque specs for the hardware supplied with this are as follows: M8-25 ft-lbs M10-47 ft-lbs M12-83 ft-lbs
CLUB-SPORT ROLL BAR: Volkswagen Mk4 Golf PACKING LIST: While every effort has been made to ensure your Club-Sport Roll Bar has been shipped complete, please check contents of package thoroughly before beginning installation. (1) 1 x Main Loop (2) 4 x Bottom Pedestal Plates (3) 2 x Pedestal Hats (4) 1 x Left Pedestal (5) 1 x Right Pedestal (6) 1 x Harness Bar (7) 2 x Lateral Bars (8) 1 x Left Main Hoop Base (9) 1 x Right Main Hoop Base Hardware Package A: 6 x M12x30mm Socket Head Bolts Hardware Package B: 8 x M8x25mm Counter Sunk Socket Head Bolts 8 x 8mm nuts 8 x 8mm flat washers Hardware Package C: 6 x M10x30mm Socket Head Stud with pre-fitted nuts 6 x M10 Stover Nuts 6 x 10mm flat washers Hardware Package D: 16 x M8x30mm Hex Head Bolts 16 x M8 nuts 16 x 8mm Flat Washers 16 x 8mm Lock Washers Hardware Package E: 2 x M12x75mm Hex Head Bolts 4 x 12mm flat washers 2 x 12mm nuts 4 x concave spacers Additional Items: 2 x Paper Templates 1 length of Edge Trimmer 1 length of.023 Wire
Step 1: Prepare Cabin for Installation - Remove front passenger seat * - Remove rear seats * - Remove hatch trim rear panel * - Remove right and left rear side trays * - Remove right and left side speaker panels * - Remove right and left rear carpet panels, amplifier, amp bracket, and wiring on left side * - Remove right and left rear seatbelt retractors * - Remove right and left door sill trim panels * - Pull carpet forward, away from rear seat - Jack up rear of car and brace vehicle following standard safety practices and equipment - Remove rear wheels and wheel well liners Fig. 01 * Refer to standard VW removal procedures as outlined in the Bentley manual Step 2: Pre-Fit Roll Bar - Using hardware Package B, bolt pedestal hats to pedestals. Fig.01 - Place right and left pedestals in appropriate locations. Fig. 02, 03 - Place right and left main loop bases in appropriate locations. Fig.04, 05 - With end links facing rearward, slide main hoop into its bases and tip into position - Install hardware kit E finger tight into main loop bases - Install right and left lateral bars between main hoop and pedestals with hardware kit A; finger tight. - With roll bar in appropriate position, main hoop bases and pedestal flanges sitting flat; mark all mounting holes for pedestals and bases with a marker. Fig. 06 - Disassemble and remove entire roll bar Fig. 02 Fig. 03 Fig. 04 Fig.05 Fig. 06
Step 3: Hard Mount Pedestals - Center punch all marks deep enough so that the marks are visible from the other side - Drill a 1/8 diameter pilot hole on all marks, then with an 11/32 diameter drill bit. Fig. 07 - The left rear pedestal plate mounting holes may have to be drilled from the outside of the car (inside the wheel well). In that case re-center punch those particular marks from the outside, then drill. - Install right and left pedestal with hardware kit D and tighten down finger tight only. Fig.08,09 - Note: In the right rear fender well, the evap line will need to be relocated. Remove the evap line from the plastic clip. Spin the clip off of the stud it is mounted to. Enlarge the hole in the plastic clip to attach it to the protruding bolt from the pedestal mounting hardware. - Reinstall right and left seat belt retractors; torque to 30ft-lb - Reinstall carpet panels - Reinstall door sill trim. Install the 3 Phillips head screws but don t clip down the rest of the piece Fig. 07 Fig. 08 Step 4: Trim Interior Panels - Cut end link holes into right and left speaker panels: Fig.10-18. - Place template on panel accordingly and center punch. - Then, drill a 3/16 diameter pilot hole. - Peel away leather from panel with scribe or pick tool. - Flip panel over and with a 2-1/4 hole saw drill almost all the way through. - Carefully cut the rest of the circle with a utility knife and remove the piece. - De-burr or smooth the edges. - Relief cut the leather into 16 sections. - Spray contact cement onto underside of panel and leather. - Pull leather back and stick down on underside. - Warm up edge trim with a heat gun (or hair dryer) to soften glue inside. - Install edge trim and cut to appropriate length - Reinstall right and left speaker panels Fig. 09 Fig. 10 Fig. 11 Fig. 12
Step 4: Trim Interior Panels (cont.) Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18
Step 5: Hard Mount Main Hoop - Install right side main loop base with hardware package C: Remove 3 grommets from underside of car. Fig.19. - Use a magnetic holding tool to feed nut/stud through the floor (middle hole) and into the top two mounting holes. Fig.20. - A second person will have to install the washer and nut from inside the car. - To install bottom nut/stud, feed some.023 wire from the inside of the car through to the first hole on the underside of the floor, make a small loop and thread the stud into it, then pull it through. Fig. 21, 22. - Bolt together finger tight. - Install main loop: - Place right leg of main loop on cup of right base. Have left leg of main loop angled towards driver s side door opening and top of main loop tilted forwards. - Pull the top of the main loop rearward and the right leg should fall into place. - Now slip on the left base on to the left leg and swing the main loop into position. - Install hardware package C finger tight into left side main loop base - Install hardware package E finger tight into the base to main loop mounting holes - Install right and left lateral bars (put a bit of grease on end link faces) and finger tighten bolts Step 6: Torque Fig. 19 Fig. 20 - Using a 5mm Allen Key in the end of the stud, tighten nuts on right and left bases - Make any necessary adjustments on end links and then tighten the bolts - Trim carpet as necessary around main loop base tube - Tuck carpet into door sill trim and position carpet appropriately - Tighten bolts for bases to main loop, right and left sides - Make sure ALL bolts are tightened down to the specs below: Torque Specs: The recommended torque specs for the hardware supplied with this are as follows: Fig. 21 M8-25 ft-lbs M10-47 ft-lbs M12-83 ft-lbs Step 7: Reassemble Cabin - Clip down door sill trim piece - Reinstall rear side trays, rear hatch trim and wiring and amplifier * - install horizontal seat belt bar (bit of grease on end link faces) and tighten end link bolts - Reinstall rear seats and passenger seats * Fig. 22 * Refer to standard VW installation procedures as outlined in the Bentley manual
CLUB-SPORT ROLL BAR: Volkswagen Mk4 Golf PACKING LIST: Inspected and Packed by: Date: (1) 1 x Main Loop (2) 4 x Bottom Pedestal Plates (3) 2 x Pedestal Hats (4) 1 x Left Pedestal (5) 1 x Right Pedestal (6) 1 x Harness Bar (7) 2 x Lateral Bars (8) 1 x Left Main Hoop Base (9) 1 x Right Main Hoop Base Hardware Package A: 6 x M12x30mm Socket Head Bolts Hardware Package B: 8 x M8x25mm Counter Sunk Socket Head Bolts 8 x 8mm nuts 8 x 8mm flat washers Hardware Package C: 6 x M10x30mm Socket Head Stud with pre-fitted nuts 6 x M10 Stover Nuts 6 x 10mm flat washers Hardware Package D: 16 x M8x30mm Hex Head Bolts 16 x M8 nuts 16 x 8mm Flat Washers 16 x 8mm Lock Washers Hardware Package E: 2 x M12x75mm Hex Head Bolts 4 x 12mm flat washers 2 x 12mm nuts 4 x concave spacers Additional Items: 2 x Paper Templates 1 length of Edge Trimmer 1 length of.023 Wire