Work continued after finally receiving some aluminum. I also received my coilovers, which was pretty exciting! I ended up going with Protechs, who worked with me to build exactly what I wanted for spring rates and bushing sizes.
I made my first really big mistake on the project, and I'm looking for ideas on how to repair it. I'll point it out after showing to process.
First, I used my .063 6061 for the floor pan by marking it out using the template. I tried a couple methods of cutting, and ended up using an angle grinder. I quickly moved to a jigsaw with metal blade, which is much faster. That gave me an excuse for buying a new tool too!
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I also got my clecos and rivets from Aircraft Spruce - cheapest. I used Cherry rivets that were structural blind - BPSQ 43 to be exact. A friend loaned my some additional clecos from his RV build and said I would never be able to use all of them - challenge accepted!
I was shocked at how much work went into measuring again to make sure the center rivet rows required. That worked out well though.
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I punched all of the holes, then drilled along my marks. I used 2" spacing for most of it. A lot of drilling!
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I love clecos!
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And he said I couldn't use them all...
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I also bought an HF air riveter - brilliant purchase. This made it 100X easier. I had never used one, and I am so glad I followed advice to get one.
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Then I got really excited to use my new tool, which led to my mistake. I used Sikaflex 221 to bond the aluminum to the frame in addition to the rivets. Then I got into a groove, put the floor pan on and started riveting. When it was finished I was really happy with the results. I then grabbed my 5000 series .050 to make the side panels and immediately realized my mistake. And it is a doozy. I forgot to wait on the floorpan until I could mark the rivet holes on the sidepanel where it would over-wrap the floor pan, then rivet those two pieces at the same time.
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So how do I fix it? My thoughts on possible options:
1. Drill out the floor pan rivets along the side where the side panel will wrap, use measurements since I can't pull the floorpan as a template, and then re-rivet both together. Threats here would be not getting the measurements dead on, wobbling a hole, having drilled rivets in the frame.
2. Knowing that the side panel is not as structural, just bonding the side panel OVER the rivets already in the floorpan, and maybe inserting a rivnut or two in the floor panel to mount the side panel in addition to the Sikaflex. This is the one I'm leaning toward unless there is a big issue with it someone can identify.
I had already planned to use 6061 for my center tunnel side panels along with Sikaflex to create a "backbone" for strength, and I know there are guys that have built Haynes with fiberglass side panels just bolted on, so I'm thinking option 2 won't really cause any issues at all. Please advise!
The jigsaw works great for curved cuts.
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So, I'm waiting for your wise input until moving forward. Thanks for all of the help!!