Aluminum panel question

[OCMark]

I'll be receiving my complete mk4 in about two weeks. I wanted to get some advice/opinions on whether or not to drill all your panels prior to removing them from the chassis? Does drilling all of them in the beginning save a lot of time? Or is it better for a first time builder, such as myself, to drill the panels when the manual asks?

Thanks!

[carlewms]

OC Mark,

You will probably get a variety of answers. I think part of it depends on the modifications you plan to make to the sheet metal.

I ended up doing following the manual therefore fitting all the aluminum after taking it off first. One caution: sometimes the position of the panels by FFR is not exactly how you ultimately want it so you should carefully make sure you are ok with the fit prior to drilling.

Carl

[68GT500MAN]

I did my panel drilling in a three step process. Step one: remove panels and mark for drilling using any of the preferred methods Step two: center punch and drill all of the holes, deburring the backside when done. Step three put in place and drill two or three holes in the frame (or aluminum) putting in cleco's to hold in place while drilling the remaining holes.
Doug

[skullandbones]

I like your thinking on this as it means handling the pieces less to get the job done and from my experience with the MKIII which I built, the panels that were installed were in there accurately. I don't think FFR has gotten worse at that process! The only one's I needed to fiddle with were the ones I took out of the boxes. I even used some of the original sheet metal screw positions to line up the panels for final install. If you are sure they are where they should be, by checking the manual against the panel install, it should work (run your finger along the edge carefully to check for fitment). I would suggest as a lot of people have that you drill the holes slightly larger than the exact rivet size as it makes the install much easier and does not compromise strength. Of course, if you are treating, painting, powder coating, etc, it makes it less likely that you will damage the finish if you pre drill. I found the foot boxes to be the most challenging to get them back together the way they came from FFR. So there it might be really efficient to do it your way. You should label panels as you are removing them. It's amazing how disorienting it can be to replace some of those oddball size ones after they have been off for a while. Good luck, WEK.

[fordboy]

I'd like to add my 2 cents here... I figured I would do a "by the book" build, and have enjoyed almost every minute. But it is interesting to note that mods that guys have done, I did not understand until after I finished that portion of the build... my next MKIV I would do differently so it is important to dig into stuff on the forums before you start. Like the lizard skin and ceramic coatings for the panels sounded like more work than I wanted to do... but after wrestling with dynamat in a finished footbox for a guy my size (and age) was no fun. And x2 on the drill and cleco process. You dont have to get carried away with the cleco's... some pictures guys have em in every hole... but every 4th hole or so helps keep everything in line. Most of all.... enjoy what you're doing and give yourself a big pat on the back when you're done.

[OCMark]

Thanks everyone for the tips and advice. Much appreciated and not too much longer until my adventure begins. ;)