bubbaisme:
Stalker floors-white one is as I got it from the "factory"-silver is after cutting to fit. One side of aluminum is covered in peel off vinyl.
bubbaisme:
Stalker floors marked & ready to cut. Temporary white vinyl on one side. 2" thick poly rigid foam layed on garage floor to cut on, using PorterCable VS jig saw and bi-metal blade.
bubbaisme:
Stalker floors clekos hold floor temporary in place whilst drilling rest of holes. Woodworking tenon gauge use to mark aluminum for center of frame tube.
bubbaisme:
Stalker floors all drilled ready to remove so I can paint the chassis. If I built another I would paint the frame first so I would not have to do every thing twice. Just have to be careful not to scratch the paint when assembling.
bubbaisme:
Stalker floors 67 holes in each floor, might be overkill but after 3 years the floors have NOT budged or buckled. Layed down 1/8" bead of caulk before screwing down permanently. Caulk was more to seal all the holes from water and rust than to glue the pan
bubbaisme:
White panel is a poster board template for the hip panels which are part of the interior sides. Poster board from Office Max is exact thickness of the aluminum which helps when bending and fitting. Every panel had a template made before working the AL.
bubbaisme:
hip panel- mirror image of the right one. Cutouts for tunnel tubes don't need to be this big. Get a high quality flat file for the edges. The file will be used for every cut made in the aluminum. Probably 50 or feet of edges to file.
bubbaisme:
tunnel panel- right one is what I got from factory & left one is after forming & cutting about 3 hours of work. The cheap bending brake I bought at Harbor freight was indespendsable
bubbaisme:
tunnel panel mounted to tunnel temporarily to test fit. Lots of different types of clamps really helps.
bubbaisme:
Poster board template for a tunnel panel. Poster board is same thickness as aluminun. Scoring one side of board allows me to bend the board.
bubbaisme:
Stalker tunnel panels & how I bend them. Cut overall shape from unfolded poster board templete tracing, mark bend lines and direction of bend then bend on brake.
bubbaisme:
cheap brake from Harbor Fake only the best chinese crap for me. It actually worked pretty well for single bends. Much cleaner bends than trying to use a block and hammer. The red handle AC duct bender was also very useful.
bubbaisme:
B4 pulling the bending bar up with the handles. Clamps are holding down the steel plate that the part bends over
bubbaisme:
Stalker tunnel panels & a seat that I am not going to use. I got Ultra Shield aluminum seats.
bubbaisme:
side panel-needs some bending to fit it to outside of chassis-this body work shows so I am trying to figure a good way to bend it to fit the frame rails without kinking the panel. Dennis has a good way to bend them using paint stir paddles that is on the
bubbaisme:
Stalker master cylinders-engine side of firewall-right to left-clutch-front brakes-rear brakes
bubbaisme:
my design and template for firewall of footbox. Clutch hole is angled off to give more foot room from the brake pedal.
bubbaisme:
original design of firewall for master cylinder from factory doesn't take in to account the skewed clutch. Side panels bent to frame w/ no kinks.
