The first footwell panels

The first panels we decided to install were the driver and passenger footwell panels. One of the main reasons we did this was A. they where the smallest and B. we where informed that these panels could be fitted without any problems or interference with any other components.

Tools you may need for this job -

A drill
A vice
Measuring tools
Marker pen
Ruler
Hand clamps
Rivet gun
Cleco Inserter tool
Files
Nibbler tool (If needed)

A sharp (preferably new) 3mm Drill bit
3mm rivets
Cleco clips/clamps
Polyurethane sealant (Available form GBS)

The first thing we did was line the drivers side foot panel up with the chassis to make sure it fit in place.  After clamping it in place we realised that the panel wasn't sitting completely plat against the chassis. When we pushed the panel in you could tell that it was bending. Turns out that some of the corners were interfering with the welds on the chassis, which was understandable. We marked where the edges needed to be cut shorter, took the panel off and went to work initially with a file.

We repeated the process of clamping the panel on and off and filing it down until we, mainly mr perfect Kev, was happy with it. We did use a nibbler tool for certain sections such as where the top left piece of the sheet bends down to make a semi circle for the steering column hole.

Another technique we used to get it was to bend the left side edge to lay flat on the chassis. This was performed in the vice and just meant when the ally sheet was riveted it didn't warp around the edges to make that awful puncture mark press effect.

Once we where happy with the position the sheet was sitting we marked up how many rivets we wanted both horizontally and vertically. After some complex measuring and dividing we marked it up and started drilling the sheet (while clamped to the chassis) with the 3mm drill bit. One thing that we made sure not to do was hit the other side of the chassis bar when drilled through, this would blunt the end of the new, sharp drill bit.

We inserted the the Cleco clips as we went along to pull the sheet the chassis together. In the end we decided to go with 5 rivet holes down, 3 across the bottom and 2 on the top, either side of the steering column cut out.

When drilling had finished the panel was taken off for the final time, the holes in the ally sheets were filed to remove any excess metal and sharp edges.

Next it was time to put the polyurethane sealant on the panel before final fitting. This just ensures a waterproof barrier and gives the panel a proper seal. WARNING before using this stuff make sure your have scruffy clothes on, its a proper bast***d to get out of your clothes, as I found out with wearing a decent jacket. All you need is a thin bead around the edges of the panel.

Finally we placed the panel back onto chassis, clamped and Cleco'd it back up and started punching rivets in. Try and make sure your rivet is flat to the sheet when you punch it in, this will avoid them being angled. After it was riveted in we waited for the sealant to dry and cut off the excess around the sides in the morning.

This same technique was pretty much used to get the passenger side panel in except it took us a lot less time because we knew how to do it this time.