Today's task was to get the main boot interior panel done. I feel I need to get the rear inside panels in place, so I can finalize the fuel system layout and supporting infrastructure for the fuel and electrics.
I fitted a cardboard pattern some time back. I transferred the cardboard pattern to 0.063 aluminum sheet. The bottom panel will be thicker than all the others at 16 gauge. All other panels will be thinner material.
Using a nibbler, Dremmel tool with steel burrs mounted plus some small hand files I went to town after trying out some techniques on a scrap piece of aluminum. This is the first time I've used the nibbler. It's hard to see where it's cutting, but it's workable.
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The nibbler maker claims it will cut 14 gauge steel. I believe it. The thing is a demon on 16 gauge aluminum. It does throw off some pretty sharp and nasty chips.
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This is as close to the marks as I could get with the nibbler. I used the Dremmel and hand files to clean it up to its desired final state.
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I'm not expecting an offer from the fab guys at Team McLaren, but not too bad for a first time "old man in a shed." Most importantly, it fits. I left a little excess material on the outer edges. I'll fine tune those when I have the actual boot body panels made, so I can fit them closely.
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Cheers,