Side Panel Blues

[BIGNUMBER2]

Hi
Im trying to fit driver side panel,I have correctly drilled holes and notches etc and aligned the panel with the top of the 38mm dia bar as per manual, but when i start to cleco pin my way round this I end up with a 1/2 inch gap at the bottom of the bend in the middle of the panel and no amount of pushing makes it fit,as this is a highly visable part of the car its got to be right, has anyone else had this problem and if so how did you get around it

[steve_d]

Did you drill the ali and the steel separately?
If you drilled the ali first then spotted through them into the steel then I cannot see how it could be misaligned.
Perhaps you need to post some pics.

Steve

[BIGNUMBER2]

yep drilled them both seperately using ally panel as guide, problem is that to make the panel align with the 38mm bar on both sides of bend i have to force the panel up and out of its natural position
(harder to explain than do) leaving the gap at the bottom , will post some pics to help clarify

[steve_d]

Order should be;
cut panel to fit including relief around welds.
Mark out and drill the panel.
Clamp in correct position and drill through into the top tube at each end and one in the middle. Cleco or rivet these. Drill through a few more along the other edges and cleco these. Form the roll over the tube. When happy with this continue and drill through all the remaining holes. Remove panel, spray waxoyle into the holes and refit the panel with mastic holding in place with plenty of clecos then rivet.

Steve

[Pilot Pete]

"drilled them both seperately using ally panel as guide"
Arrh

Dito what Steve said

[v8owner]

BIGNUMBER2 said:

yep drilled them both seperately using ally panel as guide, problem is that to make the panel align with the 38mm bar on both sides of bend i have to force the panel up and out of its natural position
(harder to explain than do) leaving the gap at the bottom , will post some pics to help clarify

for the record I have the same thing?...

I havent drilled the rivit holes yet, just notched the both panels.. however i notice the panel seems to be interfering with the footwell bulkhead verticle chassis members? I was going to remove this extra material (like a very thin cheese wedge), and am hoping that will sort it out.

Out of Interest where in berkshire are you? Im in Staines (No ALI G comments please)....

[BIGNUMBER2]

When i say drilled seperatly i mean drilled panel first then offered it up and drilled through panel holes in to the steel as per manual, i think the problem might be a run in the panel of 1/8 inch,just wondered if this was a common thing. i am in sunny bracknell

[gtr-gaz]

v8owner said:

.. however i notice the panel seems to be interfering with the footwell bulkhead verticle chassis members? I was going to remove this extra material (like a very thin cheese wedge), and am hoping that will sort it out.

I think that's common. I know I had exactly the same on mine. A lot of trimming/fitting/trimming to get it just right.

Bignumber2's sounds like it's not the right size to start with? Not sure without seeing a pic though!

[Bitzleftover]

Hi I had this same problem , and after a bit of head scratching started the skin pinning in the corner that had the gap and worked outwards from that until the whole panel was fitted prior to rivetting. It seemed to me that the preformed bend in the ally was a little misaligned but it looked sound when I had finished.

[v8owner]

Bitzleftover said:

It seemed to me that the preformed bend in the ally was a little misaligned

Just been in the garage and I think sorted it.. exactly as above.. still is a slight gap but i think riveting should pull it in without any bending...

Bignumber2 - good to know there is another build so close...!

[steve_d]

BIGNUMBER2 said:

yep drilled them both separately using ally panel as guide, problem is that to make the panel align with the 38mm bar on both sides of bend i have to force the panel up and out of its natural position
(harder to explain than do) leaving the gap at the bottom , will post some pics to help clarify

Only just realised what you were saying here.
The height of the panel at the top tube (in the door opening) is V important so that when it and the top sheet are rolled over they meet perfectly. This is not important forward of the roll bar as it is hidden under the dash and you will hardly see the top edge and certainly will not see that it runs out. Once you have the panel at the right height then it is more important for the bottom edge to have a uniform gap to the floor all the way down the footwell as you will most definitely see any run out there.

Steve

[ultimad]

OOOO.....I'm so glad I don't have to cut and rivet any panels any more...sends a shiver down my spine just reading these posts.

[Stig]

all the details you need are here:

www.ultima-gtr.info

and here:

www.ultima-canam.info