12th August
Two weeks business travel around Asia meant no progress although nut and bolt pack arrived and great e-mails from two other builders about the solid lower chassis rail – how can I fix the panel to it? No really clear answer, even from Martin though he sent a couple of photos. Self tappers?
Alistair is home and so today we blitzed through several of the drivers side panels – far easier with a helper. He had to push off about 3.00pm but by then all we had left were the drivers outer – “simple”, and the drivers rear – the one that needs bending. The “simple” one was easy to trim and place but the steel in the frame at this part seemed variable – easy to get through in some places but really tough in others, even with fresh drill bits and lots of magic compound. Two good Bosch 3mm bits I use as pilot drills snapped as I tried extra pressure. Anyway it was done, so on to the last panel. With the lessons from the passenger side I got a good sized piece of paper, made a template, redid it three times then bent my sheet on the workmate, finishing it with the soft faced hammer.
Alistair is home and so today we blitzed through several of the drivers side panels – far easier with a helper. He had to push off about 3.00pm but by then all we had left were the drivers outer – “simple”, and the drivers rear – the one that needs bending. The “simple” one was easy to trim and place but the steel in the frame at this part seemed variable – easy to get through in some places but really tough in others, even with fresh drill bits and lots of magic compound. Two good Bosch 3mm bits I use as pilot drills snapped as I tried extra pressure. Anyway it was done, so on to the last panel. With the lessons from the passenger side I got a good sized piece of paper, made a template, redid it three times then bent my sheet on the workmate, finishing it with the soft faced hammer.
Good! Then again using earlier lessons I used my cheap hole-saw to cut the holes for the seat belt anchorages clamping the sheet to the workmate. Hopefully tomorrow I can drill the rear panel holes and cut the other seat belt holes. Then I can do the tunnel top, including cutting the slot for the handbrake and flip the chassis over to do the floor. What the neighbours think of the drill shrieking away I don’t know. Catherine retreats to the other side of the house! There are about 150 holes each side of the tub inner and I drill twice – 3mm then 5mm. Shoulders aching
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