Removing Aluminum Panels - drill now or later??

[hrosenthal]

I'm up to marking and removing the aluminum panels, but before I start, I can't help seeing the obvious opportunity to drill the panels and frame now, rather than piecemeal during the build. With everything in place, it seems like all I have to do is mark the spaces with the template and drill. I've also been told to drill first if I plan to powder coat the panels (which I decided against), so I can't see any harm if all of the drilling done at once.
Any suggestions are appreciated.
Thanks.

[michael everson]

No real harm in doing that. That's how I build them. Some of the panels will require minor trimming and bending for the best fit.
Mike

[Jeff Kleiner]

In many areas you can not see where the frame members are to be able to accurately drill into them. Mark from the backside by using a sharpie to trace the tuning then remove the panel, drill it using your marks as a guide then reinstall and drill thru the frame, then remove again, clear the shavings, apply silicone and rivet. More work? Yes, but the only way to do it properly IMHO.

Jeff

[hrosenthal]

As I was contemplating the job this afternoon, I got the feeling that it might be tough to drill on center of every frame member without first marking and removing the panel. Looks like I'll be marking and removing panels tomorrow. Thanks.

[JeepFlyer]

In many areas you can not see where the frame members are to be able to accurately drill into them. Mark from the backside by using a sharpie to trace the tuning then remove the panel, drill it using your marks as a guide then reinstall and drill thru the frame, then remove again, clear the shavings, apply silicone and rivet. More work? Yes, but the only way to do it properly IMHO.

Jeff

+1 for everything Jeff said.

I'm in the middle of sheet metal work right now. Got the cuts and scratches all over my hands to prove it... WEAR GLOVES! PS footbox done, floors done, DS footbox 60% done, working on the trans tunnel and rear cockpit wall. I've learned it's not so much a jigsaw puzzle as you would think. A simple label written on them as you take them off was easiest for me. If you haven't already inventoried your box of assorted aluminum, write the name of the part on it from the inventory list. Another issue similar to what Jeff said about the frame rails, is the ends of some flanges being angled. You could beautifully space your rivets, but if you don't take into account the 45 degree angle at the end of a flange you could completely miss it and just drill a useless hole. Ask me how I know. Also there are a few accessibility issues with some panels when they're on the car. Using a large cordless drill gets in the way sometimes. I completely assembled the passenger footbox off the car before installing it. The passenger side floor and side of the trans tunnel where it met in the front was the worst. Probably installed and pulled that panel 20+ times to trim and try again. Just be patient, take your time, and divide it up into smaller sections.

[Cobradavid]

One more thing to consider: some of the factory-installed panels may not be installed exactly where you want them to be. Maybe it's better now, but my Mk 3.1 had some panels installed as much as ~3/4" off from where it should be.

I didn't realize this when I began the build and I have one F-panel with 2 sets of holes - one for where rivets would go if I used the factory-installed location, and the second set for the rivets that hold it in the "correct" location. So, make sure the panels are placed where you really want them before you mark/drill.

David

[Pierre B]

The factory panel installation simply tacks the pieces in place without actually fitting them to one another. That factory process was helpful in that it showed how the individual panels are intended to lap one another,and so I was careful to note that prior to initial removal. During the fitting of several of my aluminum panels, I thought several times that the pieces were not cut properly, and that I would never get them to fit to my satisfaction. This is where building one of these cars taught me patience. Each time, I was absolutely amazed at how much careful fitting, bending of the flanges slightly one way or another made a huge difference in the way these panels went together. I never had to settle for a sloppy fit. I could never had those results had I taken the initial factory panel placement as the final solution.

[Jeff Kleiner]

Remember guys, the panels are only put in place by the factory to facilitate shipping. You are responsible for the final fitting.

Jeff

[JeepFlyer]

just curious... (not intending to hijack the thread) ...but can you order your kit and request they not drill any holes? The rear cockpit corners came duct taped to the rear cockpit wall. It seemed pretty secure to me, and a lot of the little pieces could just be thrown in a box. Just curious is all.