Panelling (almost) Complete!

I just about finished cutting all the ali sheet out this week :)
Only the rear tub left now, which I'll save until I've finished fitting out the rear end.

Also atached my universal fuel sender to the tank (using riv nuts), and made a mounting jobbie for my relays (using a 3mm ali strip and a load of riv nuts):

Yet More Panel Bashing

Getting there on the ali sheeting now...
Got the rear seat back panel and passenger footwell panel done this week.

Also made myself a cardboard template for a battery.  I think I'm going to use an 063 size, which is about the smallest commonly available (and hence cheap!) size.

Still a fair bit bigger and heavier than I'd like, but if I make it fit it should be easy going to a smaller one in the future if I want to save some weight!

More Panel Beating

I've spent the last few weeks continuing work on the ali panelling.
So far I've done the tranny tunnel sides and scuttle bottom in 1mm sheet, and the scuttle front in 2mm sheet.

Still got the seatback to do (which is almost done), passenger footwell, tunnel top, rear tub, and side infills...
Seems to be taking me forever to do the panelling, but I'm sure I'll get there in the end!

Side Panels

I've spent the last couple of weeks fabricating and fitting my side panels.
These are made from 1mm ali sheet (1050A H14 grade, which is fairly soft, so easy to bend).
I cut them out with a jigsaw, and bent them to shape using a combination of clamps, lengths of wood, and a rubber mallet.
They're fixed to the chassis using sikaflex ebt and rivets.
They look green in the pics as they still have a protective film on them.
I'm no panel beater, so the finish isn't amazing, they'll be no doubt that it's a homemade car!

Fuel Tank

I recieved my fuel tank this week.
It was made by K4KEV from the Haynes forum.  It's a bit taller than the standard book tank to give some extra range and should hold about 7.5 gallons if my calculations are correct.
The only downside was that it's a bit of a tight fit, and was a bugger to get in!
I had to trim my rear roll bar mounts down, then persuade the tank in with a rubber mallet.
A nice addition Kev made to the tank was to add a pot to the bottom of the tank where the fuel feed comes from to reduce the chance of running the pump dry under hard accelleration.  It's also baffled inside to reduce fuel slosh.
Overall I'm pretty happy with it :)

A floor in the plan

Last weekend I fitted the floor to my chassis.
I used 2mm aluminium sheet, 5251 H22 grade.
The sheet was glued using Sikaflex EBT sealant, and riveted on a ~2" pitch with 4mm aluminium rivets.

Pause for Thought

Had a new addition to the family this week, so the build has been paused while I'm up to my elbows in nappies, milk, and baby sick!
Hopefully get back on it in a couple of months...