(Author: ikom Friday June 4, 2004,
Jun,04,2004Jun,04,2004
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Friday June 4, 2004
I get up early since the weatherman promises that the temperature will hit the high twenties. I inspect the cockpit double skin panel that was riveted the night before and it looks very good in the bright daylight. I am very pleased with the result.
I am finally going to install the previously fabricated (and subsequently stored) full rear cockpit bulkhead panel today. However, since my son will be arriving later, I decide to work on the battery tray in the interim. I fabricate a cardboard template and transfer the information onto the alloy panel and use the air hacksaw and high speed carbide bit to quickly shape it to fit the convoluted contours of the chassis. It fits perfectly on the first test fit but I am not happy that it flexes on the rack side since it is unsupported there. I decide to fabricate a support leg from some scrap alloy and use the bench sander in order to get a perfect height and finish for the leg. I set aside the piece (for future installation) when my son arrives to help with the bulkhead.
We retrieve the bulkhead panel and test fit it prior to marking it for drilling the rivet holes. The upper portion will have just enough holes to secure it to the chassis since I do not want to unduly compromise the structural integrity of the chassis roll bar hoops. We test fit the cockpit bulkhead panel, secure it with clamps and transfer the holes onto the chassis using skin pins to prevent it from moving while the rest of the holes are being drilled.
We go through the process of chamfering, applying "Waxoyl", degreasing, applying "Glue and Seal", installing the panel, clamping it, skin pinning, riveting and lapping the edges. It is once again magically the time of day to quit - 10:00PM.
It has been a good day's work and the panel looks great.
Note: The Canadian equivalent of "WAXOYL" is "FLUID FILM" and is readily available from most automotive stores It is also a better product in my opinion.
