June 2008
Side panel where it meets rear bulkhead
Notch required where side panel meets rear bulkhead
How our notches look on side panels
ALLOY PANELS
A bit of a slow start to June, lots of other things in the way to have a good run on the car. This month we hope to complete all the alloy panels, top and bottom and get onto the mechanical side of things.
We have found that although the panels are not difficult, they are time consuming.
The next stage was to get the side panels drilled and in place on the chasis ready for riveting. One thing we did find is that a fair few holes positions are difficult to drill. We tried a right angled drill, but this was too big. What we did find that worked was a small drill we picked up at a local wilkinson's. Ideal for awkward holes. Although prepare yourself for a stiff back with some of the positions you have to get yourself in to drill. We also found that the swarf and moving of panels in and out scratched the chasis and although you will probably not see when finsished, we still felt it was better to lay a bit of carpet and to literallly tape pretty much all of the chasis. Some sections will remain visible and we didn't want any scratches.
One point to seriously take on booard is that the alloy panels will be visible if you do not wish to trim your Ultima.
Something that Ultima do not offer as standard or an extra I believe. The factory prefer to leave the alloy panels as they are, and if that is what you choose to do than I suggest you make the notches the best you can and try and keep the panels in top condition. For us, we will be adding an interior as we feel building such a supercar, warrants a smart look. Leaving the alloy panels with all the rivets and notches showing gives it that kit car feel, which we know it is but we feel warrants a luxury interior. Question is, when is the best time to fit. We have done research and found a few with really smart interiors. We plan to ask a few questions to find out.
With the side panels in place, all notches complete the next panel was the front bulkhead.
Having tested, we could see that this was going to be a difficult panel to fit. And we weren't wrong, which resulted in our first mistake, and a call to Ultima for a replacment panel!
Our first attempt worked and the panel fitted, but we weren't happy and having looked at other build diaries, we soon realised why. Having looked at the build manual we could clearly see the shape the factory had made for the notches but could not get our heads round how they would be able to get the panel in place past the various sections. What we did was remove enough alloy to be able to drop the panel straight in. It fitted, with all sides sitting on the chasis sections but we weren't happy. Having looked at various other sites ours was different to all and then we relised what we needed to do, flex the panel into position. We didn't think our panel was that wrong other than we may have taken off a little more from each side but we still wanted to put it right and as the same as the factory panels looked, although they mention nothing about flexing the panel into position.
Anyway, with another panel ordered, we made sure we did fit it as per the factory and other Ultima builders.
Below you will see both panels.
Happy with notches!
Not so happy with notches!
With all top panels fitted, Rear & Front Bulkhead & side panels. Next stage is to rivet.
We Have purchased a manual gun, whether or not this will be good enough, we will find out soon. It may be required that we obtain an air operated gun to make it a bit easier.
With a stag do in Benidorm just around the corner, then a house move. I can't see much more than the riveting being done during this month.
All panels finsished and in place waiting to be riveted
How our front bulkhead panel sits
Notch on front bulkhead
Master cylinder cut-outs in front bulkhead
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