GRP sides a bit tight (in places!)

[jps]

I've been dry fitting my GRP sides and found that they vary between being just right, too loose and too tight.

This is probably partly because I have gone for a 3mm alu floor and there are some areas where I can dress a couple of welds and maybe get 1mm back to work with...

Just right I can deal with.
Too loose is not so bad either - thanks to seeing how Sylvain has dealt with similiar challenges here: http://forums.haynes.co.uk/showthread.php?t=13363

The 'too tight' bit has already led to me putting a small crack in the gelcoat - presumably from trying to flex it too far - so I am not going to force the panels in place.

Any tips for what options I have to make things fit? Can I sand out the inside (i.e. the non-gelcoat side) of the panel to introduce a bit more room?

[vmax1974]

You will be able to samd some of the glass resin side where it is too tight everyone has this problem and i am looking into ways of adding a mm leaway but i havent had any ideas yet that havent meant i have to remake the moulds

[Cropper]

I removed the bottom return (but left the radius) & fastened the side panels with heavy duty velcro, then just ran a small bead of silicon along the inside. I used a 5mm dome head bolt at the front & rear for extra security, the rear one isn't seen & the front one isn't noticeable as its low down by the bottom wishbone, also used black bolts on black side panels.
The velcro works well & it's takes a lot to reomove the side panels, i also used it to fasten down the top of my transmission tunnel, which makes for easy access if reqd.

[vmax1974]

I will add the sides to my list of new moulds

[Ben_Copeland]

As above. Reduce down the thickness of the lip if possible.

I managed to get mine on without having to take any off. They were tight in places but gentle pressure slowly working along got them to stretch enough.

[Rosco]

on mine, (equinox) one side fit ok and the other side was to tight and wouldn't go on, i used a sanding flap wheel in an angle grinder and sanded the inside edges till they went on, i did have to take quite a bit out if i remember correctly

[jps]

Thanks everyone, my panels are Equinox also so good to know it's not just me!

[twinturbo]

Original saturn pannels.

3mm Chequer plate floor.

Cut the lower lip off.

[jps]

Original saturn pannels.

3mm Chequer plate floor.

Cut the lower lip off.

How did you attach them to the chassis?

[twinturbo]

not finished but will use a length of angle to pull them in.

TT

[jps]

Thought i'd update - I bonded my 3mm alu floor on - and went to the bother of countersinking the rivets where i expected the GRP side to overlap.

I thought i'd just get away with cutting the lower return off in the area where the scuttle sits, but in the end have had to take off all the return where it would overlap the floor.

Hopefully a couple of well placed riverts and lots of Sikaflex will mean it still looks OK when I fix it on permanently.

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/23659687_10155030651416723_6314490942211227381_n.j pg?oh=0c11e55f6dc2c7757fefa96c8c58efd6&oe=5AA31799

[voucht]

Hi,

Good to see you are moving forward with the fitting of your GRP body kit.
Yes, it is a lot of trimming, and it can be a bitch!
When I fitted my side panels, I was luck enough to be able to entirely fit the return under my 3mm ally floor, just with a rubber harmer used gently.

Good luck with the rest! Keep us posted :)