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Sealing around the fuel tank fixing holes |
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Again around tank bolt hole, under the back end |
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Sealing around the turret |
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Marking for drilling holes |
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Boot floor support to back panel prepared for drilling |
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The line of rivets holding the boot floor support in place |
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Holes cut for removable tyre / luggage rack |
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Piece of L to close holes for tyre rack |
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Holes taken from underneath |
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Tank fixing holes now sealed |
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Underneath fuel tank with L in place for fixing back panel, a U would be used if no tank floor. |
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Marking with pen to cut the side of joint of back panel. In line with small hole for roll bar |
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Trim back the vertical to fit chassis tube. These we have found can vary by 25mm! |
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Marking with tape the perfect line for final trimming of back panel |
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Bottom marked for final trim |
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Close up showing ideal position for trimming |
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Ready to come off and sand to tape line |
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Boot side fixing U cut to size |
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Turned edge under the side of the back panel trimmed to size |
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Again checking trimming and fit |
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Sill protector / fixing for outer skin cut to size |
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Half round sill protector / side skin fixing |
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The 2 parts ready for internal and side skins to rivet them in place |
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Front U section for fixing front side skin |
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Front end closing plates and U over the top of the chassis channel |
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Had to cut around pedal box and scuttle panel. Would not fit in 1 piece? To be glued in place later. |
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Marked up with a template. Hole cutters used to cut radius and steering holes |
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Now to join up the holes. Must make sure it is the right holes so placed tape on to show clearly |
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Done, now to clean up the holes |
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Does it fit? Mark up top edge ready to trim to fit perfectly |
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And trim line where the sill protector is. Sill will be internal not over hanging. |
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Checking fit against the front edge. |
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Trail fitting of side skin. |
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Kevlar / foam composite crash protection |
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It will absorb more energy and sharp impacts are less likely to penetrate through. With Aluminium honeycombe energy is transferred from one surface to the other, with this special foam, designed for the job, localised absorbtion is the key. |
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Cross section of the sandwich crash protection. Lighter than the aluminium honeycomb. |
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With the added 1.3 - 1.4 mm thick laminate on each side these panels are lighter and should be more efficient than other alternatives. |
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