(Author: ikom Friday May 14, 2004,
May,14,2004May,14,2004
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Friday May 14, 2004
Nice day - sunny but a little cold, I got home at 5:00PM and decided that we could get some work done on the ULTIMA. We pre-fit the driver's side panel with a bunch of clamps - check and double check that everything is lined up exactly as we want it and start drilling into the chassis. We substitute "skin pins" for clamps as we progress. The new cobalt bits work really well but by the time we are done on the panel even the cobalt bit is showing signs of wear. We are going through a lot of bits but I want them new and sharp to keep up the quality of the drilling.
We continue with the passenger side panel. We finish drilling at around 10:15PM and call it quits.
You may have noticed that we are sequencing our panel building a little differently from what the factory recommends.
Our sequence is as follows:
" Familiarize yourself with all of the factory panels
" Use cardboard templates to mark out all of the obstructions - they are a lot easier to adjust and cheaper to redo.
" Use the templates to transfer cuts to the actual panels
" Pre-fit the cockpit panels within the cockpit area
" When absolutely satisfied with their fit turn chassis over
" Pre-drill floor pan (belly pan) panels with the chassis upturned.
" Set aside (do not fasten) floor pan panels
" Turn chassis upright
" Pre-drill interior side and front bulkhead cockpit panels
" Set aside interior side and front bulkhead cockpit panels
" Upend chassis once again
" Bond and rivet floor pan (belly pan) panels
" Turn chassis upright
" Bond and rivet interior side and front bulkhead cockpit panels
" Final pre-fit, align and adjust double skin (interior) floor panel
" Bond and rivet double skin (interior) floor panel
" Revert back to factory panel fixing sequencing
We are doing this because I want to be absolutely certain that everything is lined up before I start drilling in the cockpit area since it is the most visible part of the car and I want no misalignments or regrets in this part of the car.
