alloy panelling ultima

[spatz]

my kit will arrive in 2 weeks and I am now preparing for the allow panelling.
the manual and most build diaries are drilling the alloy panel first and then drill the holes.
I wonder why you cannot fix the alloy panels with the skin pins (drill these holes first)
and clamps and then drill both holes at the same time ?
You could still deburr them individually if necessary ?
Then with the space at the footrest, has anybody used appropriate size square alloy tubes
cut to size instead of bending the panel ?

[Steve_D]

The normal technique is to cut and fit the panels carefully to fit around the tubes and welds. I found breakfast cereal packets have just the right grade of cardboard to make templates.
Stick masking tape along where you are going to drill and mark the drill hole positions. Be careful how you mark them out as on some of the rivet lines you can't drill the last hole in the line as an angled tube is in the way.
Drill one of the holes at each end and hold the panel in place with pins then drill all the holes straight through ali and steel. Remove and deburr the chassis and both sides of the ali.
Squirt some anti-rust into the chassis. Clean and degrease all parts using brake cleaner before applying the sealant. Hold the panel in place again with the panel pins and insert all the rivets to make sure they still line up. Run along all the rivets with your air driven rivet gun. Do not try and do this with a hand riveter you will do yourself a mischief.

Steve

[andygtt]

Steve_D said:

Run along all the rivets with your air driven rivet gun. Do not try and do this with a hand riveter you will do yourself a mischief.

Steve

Blimey your showing your age now Steve... I did all mine by hand lmao

[spatz]

that is exactly the way i intend to do it thanks for telling me

[Knotty]

I used square alloy tubes instead of bending the panel.
Seems to give a better finish.

[pilbeam_mp62]

Knotty said:

I used square alloy tubes instead of bending the panel.
Seems to give a better finish.

I thought of doing this, but ended up just bending them because I think you will end up scuffing the backs of your shoes on what will be a sharp corner.

Each to his own though...

Regards

[Knotty]

Here is a better picture.

[V8OWNER]

I borrowed an air riveter, but was interested to find out sealey now do cordless ones.. havent tried in but looked really good, and meant you havent got to have the whole compressor thing going on..

Either way you defo need power.. there are ALOT of rivets...

[GTRMikie]

andygtt said:

Blimey your showing your age now Steve... I did all mine by hand lmao

So did I. I got through two Halfords hand riveters (and I'm only a few months younger than Steve)

[spatz]

yep knotty this will be my way as well, the sharp edges can easily been taken care off, but thanks
for the hint.

[Steve_D]

Knotty said:

I used square alloy tubes instead of bending the panel.
Seems to give a better finish.

I really can't see the need for this.

1. When complete you will hardly be able to see it down in the darkness of the footwell.
2. If it is being done because getting it neat and tidy is difficult then wait until you do rolling the side and top skins round the tube.

Steve

[738 driver]

I used sealed rivets Spatz, as opposed to the standard factory pop-rivets, merely for additional corrosion protection as I live in a particularly damp area of the UK!
Rivetting also done by hand....casually over about four evening sessions....a celebratory glass of Rioja seemed to ease any post-rivet tension!

[spatz]

i am probably a rivet expert since I was building flight cases 15 years ago to make some money
during studies and I have a very professional german made (HONSEL) air rivet gun with integrated
vaccum for the pins. so that is not troubling my mind.
I also bought the latest hand operated model of them that has the turnable head and the adaptors
for rivnuts, so the tools are waiting.