July 2005

ikom Ultima Build

Welcom to visit my home

	Preparing for the build

	April 2004

	May 2004

	June 2004

	July 2004

	August 2004

	September 2004

	October 2004

	November 2004

	June 2005

	July 2005

	August 2005

	September/October 2005

	November 2005


Work appears to progress - very slowly

July 2005

Page 1 of 16 , there are 62 images in this channel.

Title	Clamp feeding frenzy at the sill cover cut-outs
Description	Friday July 1, 2005 I continue work on the sill covers and mark the rest of the rivet holes - on the door/side pod edge and also the two ends (front and rear). I centre punch these and drill them on the drill press. I position the sill covers and clamp them so that they line up with my previously marked registration points and carefully drill two initial rivet holes for securing the sill covers to the chassis with skin pins. Once the skin pins secure the sill covers and they cannot move, the rest of the holes are drilled. The next task is to bond the solid rectangular bent square rods shaped to serve as lid spacers to the underside of the sill cover panels. While other builders apparently elect to bond them to the chassis first, I think that there would be greater control (of establishing tolerances) if they were bonded to the undersides of the sill covers and the whole assembly subsequently bonded to the chassis. I clean the bonding surfaces with degreaser and apply a thin coat of Wurth Glue and Bond to each sill spacer and place it in position so that it sits just beyond the edge of the lid cover cut-outs by about 1 to2mm. I then use every small clamp that I can squeeze into the cut-out to bond the spacers to the sill covers while adjusting the distance from the edge of the cut-out to the spacer, so that it is even all along the perimeter. I leave the assembly to dry - or rather until the Wurth sets up. The result is an even lip of approximately 1mm overlapping the spacers, which is what I wanted to achieve. I will leave the panels to bond overnight; I clean up and call it a day.
Size	182.96K
Date	Jul,01,2005

Title	Clamped sill cover cut-out edge to bond spacers
Description	Clamped sill cover cut-out edge to bond spacers - note view of sill cover underside is on upper right hand corner of picture
Size	155.49K
Date	Jul,02,2005

Title	Clamped sill cover cut-out edge to bond spacer - close-up
Description	Clamped sill cover cut-out edge to bond spacer - close-up Note: very little bonding material is needed.
Size	167.98K
Date	Jul,02,2005

Title	Finished sill spacer bonded to edge of sill cover
Description	Finished sill spacer bonded to edge of sill cover - The bonding material will have to be carefully removed. A 1mm space is left around the perimeter of the sill cover cut-out.
Size	77.64K
Date	Jul,02,2005

Page 1 of 16 , there are 62 images in this channel.