Dakar Body off Restoration -
Had quite a large parts ordering session in order to complete the build:
Full sheet of 16 Gauge NS4 Ally -
Rustoleum Combicolor Satin Black
Cleko kit, Rivnuts, Stainless pop rivets and sikaflex from Car Builder Solutions
Wire, Crimps and slitted conduit from Vehicle Wiring Products
Starting with a whole sheet of NS4 ally, I created a template for the return edge in the rear wheel arch and then used a jigsaw to cut out the shape.
By clamping the panel to the bench, I hand folded the two angles on the panel (I used a protractor to measure the required angle on the car).
With the completion of the side panels, I realised that the battery boxes were in a very poor condition. This was due to the fact that I riveted bare unpainted steel together (due to my impatience at the time to get the car finished). So lesson was learnt there. I flattened the old boxes with a hammer to create the templates for the new ones.
Unfortunately I only had 16 gauge steel available -
Once complete I sent them off to Milton Keynes Powder Coaters (Alpha Metal Coating) and had the coated in RAL5017 powder. I also painted the chassis as I have always hated the grey colour.
The original kit has fibreglass arches -
In the second picture you can see my new tool; It’s a digital protractor -
A little more work to make some end caps
3mm checker for the floor, more powder coating and were done..