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View Full Version : Aluminum panels: tips & tricks?



MPTech
05-09-2011, 08:41 PM
I posted this on the other site, but really want to make an effort to building history here.
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I've had my kit for 5 weeks and been casually working on it between honey-do's and family obligations. HAVING FUN!

One of the first things I did was marked all of the Alum panels (where the braces are, overlaps, underlaps, notes, etc. (I wish I had thought to take pictures!). I have most of the panels removed except the rear bulkhead and PS footbox.
Meanwhile, I assembled the IFS, installed the Power Steering rack and tie-rods, installed the steering shaft, linkages, and steering wheel. I also assembled the IRS shocks & suspension. And fitted my '94 Pedal assembly.
I haven't installed the brakes or brake lines yet, that's my next milestone. And I'm waiting for the differential to be put together, (rebuilt Trac-Loc, new bearings, and a new set of Ford 3.55 R&P gears).

So, I grabbed my first Alum panel (DS footbox floor pan), marked the holes, and drilled them with my drill press (using my new shorty, double ended bits). Piece of cake! (I wasn't expecting a problem there anyways).
Now comes the fun, I re-attached the panel with the original metal screw for initial positioning and aligned and clamped the rest of it in place with a couple spring clamps. In retrospect, I'm thinking I should have drilled all of the panels and assembled the whole footbox. before drilling the chassis.
Anyways, I laid on my back and reached sideways under the chassis and drilled the first hole on the opposite side, from the ground up into the bottom of the frame. About what I expected, a PITA. It worked, but I knew my arms / hands wouldn't last drilling all of the holes like this. So I drilled about 4 or 5 more holes, installed some temp screws and called it a day. Then took 3 Advil!

My question / assistance is: with the large body of knowledge and experience with this, and since everyone has HAD to do it. What are the tips and tricks of this laborious task?

btw, I do have some Clecos, but just didn't use them.
I've heard some tips (and mentioned a couple already, but wanted to try to compile a list for my benefit and other future builders).
(I did a couple searches, but didn't come up with any all encompassing lists)

Thanks Guys!
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3kcarbon
05-09-2011, 10:12 PM
Clecos Rock! Use them!
Trial fit then drill and cleco in place. Fitting out of the car isn't always the same as how it will be in place. Remove everything and remove the drill debris. Mark everything and takes photos to refer to later.

Pierre B
05-13-2011, 09:14 PM
In most cases, the folded 3/4-inch edges of the various panels need to have their fold angle adjusted and fitted to both adjoining panels and the chassis surfaces to which they will attach. Don't assume that the quickly tacked factory-attached panels received any of this fitting attention: they are secured to the chassis at FFR simply as a guide as to what panel edge flange fits over/under what adjoining piece. I can't tell you how many times my initial try at panel placement and fitting made me wonder if I even had the correct piece in hand. I really learned patience during this metal panel installation, and I believe it really paid off. Given enough time and attention, the FFR factory panels really fit very well on my MKII chassis: frequently much better than I had actually thought possible, much to my delight. For me. it was mostly a matter of getting the panel edge angles right, and not giving up on any one piece until I got it just right. Otherwise, one panel mismatch will beget another, and so on all around the cockpit. Also, I did not drill any of the panels until the fit was right. Clecko fasteners are absolutely INDISPENSABLE for this process, IMO.