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]

Originally Posted by twinturbo

Original saturn pannels.

3mm Chequer plate floor.

Cut the lower lip off.

How did you attach them to the chassis?