Gaps between GRP panels and chassis rails

[voucht]

Hi,
I trimmed my bodywork panels as much as I could and now, everything (temporarily) fits together. However, I have big gaps at a lot of different places


2014-06-26_18-48-05 par Voucht71, sur Flickr

(other pictures pictures).

With the side panel top edge being to high (8mm gap between this edge and the top side of the top rails), my nose cone needs to be raised of more than 10mm! So here again, I need something to fill the gap.


2014-06-26_18-55-43 par Voucht71, sur Flickr

Of course, these gaps are not regular: when I have 8mm at the front, going backwards, it is going down slowly to finally touch the top rail nicely at the scuttle level.

I planned to attach my side panels to the chassis with rivnuts in the top and lower rail (I want my side panels to be removable) and bolts on the top edges (countersunk where there will be the bonnet on top) and bottom edge of the side panel. But with these gaps on the top edges, (bonnet and cockpit level), I feel like I won't be able to correctly tighten the bolts without braking the GRP. Am I right? So I think I need to pack these gaps any way possible.

I bought rubber bands and trims in different thickness’s, but I'm not sure it is the ideal things to fill these gaps. And I'm wondering if rubber is really a good idea as it will be kind of soft anyway, and I'm afraid the GRP panel moves too much and end up cracking, or even worse: braking.

So, what would you do if you were me? Any advices or ideas?

Thank you very much in advance.

[jason 82]

If you tighten the fixings over a couple of days the fibreglass will start to take the shape of the rails. Put a large washer (temporarily) under the bolt head to spread the load, & you should be fine.

[voucht]

Thank you for the reply Jason, but I really don't see how the GRP can take the shape of the tube: the 90° corner of the top edge and the side panel will stop me to achieve that I think. Look at the first picture of my post : I think the surface to shape is way too narrow for that (25mm wide), and the gaps are too big.
But thanks for the tip

[Ben_Copeland]

Have you got your floor on yet?

That would make the panels a little better fit

Otherwise I'm not sure what you can do, your chassis must be out as the side panels are usually a tight fit !

[jps]

Originally Posted by Ben_Copeland

Have you got your floor on yet?

That would make the panels a little better fit

Otherwise I'm not sure what you can do, your chassis must be out as the side panels are usually a tight fit !

Sylvain - on the same theme as Bens comment - but a different approach - could you put the top of the panel flush (ish) and move the problem to the underside of the car? Just thinking it may be easier to make a less attractive solution down there..?

[TheArf]

Sylvain, who manufactured the panels for you, can they give you any advice

Arfon

[jps]

Originally Posted by voucht

Hi,
I trimmed my bodywork panels as much as I could and now, everything (temporarily) fits together. However, I have big gaps at a lot of different places


2014-06-26_18-48-05 par Voucht71, sur Flickr

(other pictures pictures).

Sylvian, I've just trial fitted the first of my side panels today with a setup similar to yours (3mm alu floor) and found a gap much like the one in your picture above. Any tips on how you addressed that particular gap? At the top, where the panel meets the foot of the roll hoop my panel sits about 10mm above the metalwork...!

[voucht]

Hi,

Yes, this space looks weird at first, but finally, it is not such a big deal.

I haven't actually fill this gaps between CP11/SS1 and the panels, as with the seats in place, they are not visible, and nothing pushed on the edge there. But I filled the gaps between TR3/TR4 and the panel (with aluminium spacers), because that is where you push with your hands when you extract yourself from the car.

http://vouchtroadster.blogspot.fr/20...panels-09.html

To come back on the space between CP11/SS1 and the panel, I had same problem as you at the top, where the panel meets the foot of the roll hoop. Not very nice, especially because it is not levelled with the rear tube where they meet.

2014-10-04_15-38-54 by Sylvain ROIG, sur Flickr

My solution has been to level it and trim the edge in a nice curvy shape to meet the curve of the side panel:

2014-10-04_15-49-42 by Sylvain ROIG, sur Flickr

2014-10-04_15-49-35 by Sylvain ROIG, sur Flickr

to be followed on the next post (can't add more pictures on this one)

[voucht]

I completed the work by put nice slick trim on the edges. The curvy part of the side panel does not go up to the foot of the roll bar, but I'm not unhappy with the result.

The trim goes from the rear tube to the dashboard, and it is not that bad.

2014-10-04_16-58-33 by Sylvain ROIG, sur Flickr

2014-10-04_16-58-41 by Sylvain ROIG, sur Flickr

Hope that helps

[jps]

Originally Posted by voucht

I completed the work by put nice slick trim on the edges. The curvy part of the side panel does not go up to the foot of the roll bar, but I'm not unhappy with the result.

The trim goes from the rear tube to the dashboard, and it is not that bad.

2014-10-04_16-58-33 by Sylvain ROIG, sur Flickr

2014-10-04_16-58-41 by Sylvain ROIG, sur Flickr

Hope that helps

Cheers- I really appreciate the pics - my first thought was to loose the return on that curve entirely so the line of the original metalwork is followed on the outside and somehow trimming the vertical edge so it has a nicer finish on it. Your solution - to effectively 'cut the top off' the curve - does make sense and looks fine I think!

I am fairly sure I have no other room for adjustment as the panel sits pretty tight on the rails down the whole side of the car - I may even need to sand out the returns on the inside slightly to try and introduce a bit more space to work...!