Wheel arch - will rivets hold it!!!

[TrevS]

Hi all

I am trying to fit one of the aluminium panels to my car but when its pressed into place the panel doesn't sit flush and one of the edges is alway trying to push out and requires some force to get all edges against the rails.

The question I have is if I rivet it into place using my aluminium rivets will the panel hold into place ok or will it cause pressure on the rivets which overtime could pull through?

Here is a video showing the issue
YouTube - GT40 Wheel arch panel pushing away from chassis


As I am new to rivetting and panel fitting I don't know how strong they are and whats acceptable amount of strain to put on them

Thanks

Trevor

[Tornado Sports Cars]

Trevor

It looks like the diagonal fold needs increasing a little.

Andy

[Phil]

Trevor:
I am assuming that you are bonding the panels as well as riveting so that will give you some additional strength. Also from your video it looks like there is a bit of interference from the weld at the top of the suspension attachment where the panel sits. A bit of beveling on the inside of the panel should correct the fit somewhat.
As far as the rivets, depending on what size shank and head you have you may be able to size up your shank and keep the head diameter the same in order to get a stronger bond, but the panel must be flush as I am sure you have found the rivets need to be set fully as they don't pull in like a bolt.
It appears also that the panel needs a bit more of a bend in the diagonal line, and some taken out at the bottom...just a slight tweak.
I would suggest more rivets along that bottom rail, but I suspect you are spacing your rivets to get a uniform look and it would not present a well-planned job.
I always use stainless rivets in the difficult areas, and there is always some discussion about the reaction between the aluminum and the rivets, most of the chassis are not seeing the conditions that cause the corrosion on a regular basis so we use them.
One question I would have is if you using closed end rivets for attachment, and what head size are you using?
Nice build by the way, keep up the good work.
Cheers
Phil

[TrevS]

Thanks guys

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We've decided that the panel needs a little more folding along the diagonal line so its going to increased by about 10 degrees tomorrow which should get the panels sitting much closer.<o:p></o:p>
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Phil, thanks for your comments on the trimming etc too, we've trimmed most of the panel but your right there are a couple or small areas that need a little attention to get just right.<o:p></o:p>
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Also I am currently using the standard rivets supplied by Tornado which are aluminum, 4mm rivets that I believe are closed end. I am though going to try and source the same size rivets but with a slightly longer shank for the arches to ensure the rivets set well in the chassis as I am worried the current rivets will be just a little too short where there are a couple of pieces of aluminum overlapping and being sandwiched together<o:p></o:p>
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Trev<o:p></o:p>
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[KarlB]

Trev,

I have just completed the same panel today as you are discussing, looking at your u tube video it is clear that you have not got the angles correct in one or two areas [including the diagonal] + as mentioned above have not cut or folded or filed back to allow for welds

I am panelling a tornado like no other at the moment, as close as original in appearance to a real car as one can get using a box section chassis .....i have learnt the hard way and give the following advise that may help having completed approx 40 -50 complex panels

1. Make card template
2. Fix card template in position as if it is the finished panel using cleco's, them template the finished angles again in card
3. make aluminium panel, bend to templated angles.
4, fit ali panels & check if correct with card templated angles, if not the same amend

My panels are being painted black so i do not have to worry about minor gaps as the panels are sikaflexed & sprayed in 2 pack, but if you are leaving yours in ali be careful of gaps around the lower suspension mounts as this can lead to water ingress. my panels have folded back tabs at these points rather than just being cut round the mount [if you want a pic PM me]

Hope i have assisted

Keep up the good work

KarlB

[TrevS]

Thanks for the info Karl

To be honest my panel isn't far off your picture I don't think the video shows the panel clamped into place very well. I know there are a few places that need a little trimming but I always try to leave too much on the panel to start with rather than not enough and then trim as required.

As for cardboard templates I alway make them first and size wise the templates are 95% accurate everytime but folding card and aluminium is very different so the results will always differ slightly.

Also I am having my panels powder coated and will make sure that any gaps are properly filled to avoid any water ingress.

I'll post some pics up once the panels are fitted and hopefully they will look ok.

Trev

[TrevS]

You can see my card templates in an older picture from my build:


Everything fits perfectly

Trev