RS Blog 7 - Finally Attached Panels to Ultima

Sep 1

While this project has unfortunately been put to the side for far too long, I’ve been harassed enough by Garrett to start making holes and finalizing things. The biggest challenge for these panels is they will be permanently attached, therefore if it isn’t aligned correct it shall bug me forever more.

For those curious about building an Ultima or any other kit car with aluminum panels, please keep in mind you will literally spend hours dealing with hundreds to thousands of holes.

Aligning….

Marking….

Center punching….

Drilling….

Removing shavings to prevent random swirl scratches…..

Deburring….

Deburring the other side….

Deburring the chassis side….

So yeah after 338 rivet holes on just the floor alone I’m all for any and all tools to speed up things and remove hand cramps.

As this progressed I ended up buying a battery powered caulk gun, the sealant for panels is almost impossible to squeeze out by hand. Air rivet gun was also clutch. Enjoy some pictures over the past week or so getting through the bottom panel final attachment.

Super important if you have a splitter

Drill holes for the mounting screws otherwise you’ll be sorry later, instructions from Ultima don’t actually mention this detail. I believe I will also need to drill holes for the front tow hook as there are three large through holes in the front. I have access from the other side and will confirm before fitting my front double skin panels.