More Panel Trimming

Had some time to continue the work on the front section of the driver's side panel. Finished the cut for the exhaust pipe. Took the panel to the car for a test fit and it did not go as I hoped. I thought I could put the panel in without taking the exhaust headers from the engine. Unfortunately, when I slide the panel passing the exhaust headers through the hole, it hits the chassis and does not fit.

Took the headers off and then did a test fit without them. Noticed that an additional part of the lip must come out otherwise I can't fit and remove the panel using rivnuts. Anyway, to validate the hole, tried fitting the header through the hole to get it in place and I couldn't. It hit the steering column and I couldn't twist it into place.

Took the panel (and exhaust headers) back to the storage room (where I've been working the past sessions). Cut the extra bit on the lip and filed away the whole to make the curves nicer and give a bit more room on one corner. Left it there, will test fit again next time. Hopefully, will only need some small filing.

Driver's Side Outer Panel Cutting

Today just worked with the dremmel and cutting disks. Actually also used a small electric saw for a bit, but shouldn't have...

So, first drew a line on the driver's side panel to mark where to cut. Idea is to separate the rear 2/3's from the front third. The rear gets riveted in place, the front will be held with rivnuts to allow easier access to oil filter, brake cylinders, etc.
Doing the whole straight line with the dremmel was going to take forever. So, after cutting the tips, used the electric saw. Problem is that I can't actually cut a straight line with that and it notices a bit. I filed the parts a bit to hide the small waves but it's not as good as it would have been with only the dremmel. I wonder how much it will be noticeable on the car. Anyway, in retrospect, I shouldn't have used the saw.

Offered the front part to the car to check where I had to cut the upper lip due to the engine cradle anchor points. After trimming those two spots down (just with the dremmel), moved on to the exhaust hole. Transferred the template I did last week and started cutting. This time using just the dremmel. But I did not have enough time to finish the cut. More next week...

Templating for Exhaust and New Rivets Plier

During the week went to the shop where I left my broken big rivet plier waiting to see if I had any warranty on it. Since the importer has closed, they did not manage to contact anyone for that and I came back home with the broken thing. Anyway, it was replaced with the lazytongs one. On the shop ended up buying a new small one to do the rivets under the car.

Looking at the picture, it doesn't seem too different from my old one. On the top is the cheappo garbage, below the new one. When not compressed, the new one opens a lot more. And it actually pulls a 4.8 rivet in just 3 pumps! The price difference was negligible and this is another example that going only for cheap tools seldom pays off. Putting the 11 rivets on the passenger's side was a breeze.

Then I checked where to cut the driver's side panel to split the part to rivet and the part to hold with rivnuts. Last task was making a template to know where to cut the hole for the exhaust to pass through the panel. Picture shows the template loosely held, since I had already removed it when I thought about taking a picture for the blog.

Next session(s) will be with the dremmel and cutting disks working on the panel.
Scheduling will now become even more infrequent, the baby was born a week and a half ago.

The Underside Of The Exterior Panel

Last time I left the car with the passenger's exterior panel riveted only on the top part (missing two rivets under where the scuttle currently sits). Today I wanted to do the underside of the panel, so that I could consider it done.

First, had to raise the side of the car and put two axle stands to get it tilted so that my drilled could fit under the car. I was not feeling comfortable, afraid the car could fall and hurt me, but took extra care to never get under the car or too near the wheels.

After tilting the car, used some clamps to bend the front third to the bottom chassis rail. After that, drilled the first hole (on the front end). Putting the rivet was harder; my "lazy tongs" riveting pliers did not fit under the car. Went for my feeble basic rivet pliers and tried that. After squeezing it some 60 times, the rivet was installed. I can't withstand doing all rivets with that, but just the basic ones to get the panel in place are OK...

On the rear end of the panel, I had nowhere to attach the clamps to. So I used a big stretch of tape to glue the panel to the chassis. It lasted enough for me to drill the hole and insert a second rivet. Also inserted a third where the frontal third of the panel ends. All other holes were drilled but I'll put the rivets after buying a new pliers that fits under there.

Put the car down and packed to go back home. Next week, I'll start on the passenger's side.

Little note to the fact that I'm feeling exhausted, for the second week in a row. This drilling has been physically demanding and I'm actually in a worst state than I thought. Oh, and the baby is late; wife on 40 weeks yesterday, no signs of the girl wanting to come out.

Riveting the Passenger's Outer Panel

Spent the morning riveting the passenger's side outer panel. Used 4.8 rivets spaced 100mm centres. On the "cockpit", and since the panel has a "U" shaped lip, riveted on the inside of the car. On the engine area riveted on the top of the chassis rail.

Only riveted the upper part of the panel. It was incredible that it took me around 2 hours to drill for and apply 17 rivets. The ones on the side of the chassis, I could not apply the weight of my body on top of the driller. It was all forced with my arms. Got tired and spent around 1h30m to do 11 rivets. The other 6 were on the upper side, could put my weight behind the driller, got all done in just a bit over 15m. No point in taking pictures, not that different from when I fit the panel.

Two rivets still need to be applied but I had to take the bulkhead out to put them and my time was almost up, so I had to leave that for the next session. I'll also still have to work on the lower side, probably will tilt the car with two axle stands to rivet underneath. Lets see how that goes.

Engine Bay "Spring Cleaning"

Some car time today, started "unclogging" my can of PU adhesive. It has not dried to a rock, so after half-hour on it, it's ready to use. I have to get that on the panels before riveting.

Then went to the car. Some time ago went with the wife to IKEA to get some stuff and saw some convoluted tube pretty cheap. Bought some and today used it to give the engine bay a face-lift. I was very happy with the result so far, better than I expected. Not completely done because I still lack clamps to join the wires to the battery. So, I didn't work on those wires. Nor on the front lights ones, since the lights aren't fitted yet. A before and after pictures are worth a thousand words...

Next session will be PU on the passenger's side exterior panel and rivets.

Little That Looks Much

Finally had a bit to work on the car, now that the new baby room is almost ready. First task was to fit the rear wheels again, so that I could put the car on the floor. Took longer than expected, but it was good to see it on 4 wheels again.

Then I grabbed the passenger side panel and fitted it. The car looks great and it made a lot of difference just to add that block of ally!

Did not get around to rivet it. That will be the next session. But looked into where I'll be cutting the panel on the driver's side so that I can remove the front part and have easier access to brakes master cylinders, oil filter...

Before going away, checked if the toe on the front was good (by counting the number of exposed threads on the steering arms, compared with measurements sent to me by Iain). Nothing to do there, which was great (and unexpected).