Body Panels

 I decided to splash the cash and buy new aluminium sheet for my Locost body panels.

3 new 8ft x 4ft sheets cost £93, sweat appeared on my brow and I could not afford to waste any of this material, so planning was needed. I had access to thin cardboard layer pads which are used in the food canning industry between each layer of cans on a pallet. They are a good size about 1050mm x 1200mm and although thin, they are very strong.

Before I cut any aluminium sheet, I worked totally with cardboard body panels. The book once again gives the position of the Locost body panels and panel drawings. Each panel was marked out on the cardboard sheet. It was then cut and folded. Each panel was offered onto the Locost chassis and taped into position to check alignment.

It does not matter how accurate the size is, uneven lines are very easily picked up by the human eye!

If a hole was cut slightly out of position, I would tape another piece of card over the area and cut a new hole until I was satisfied. The rear Locost panel was more complicated especially where it folds over the top edge of the round steel tubing. To make the panel fit good, lots of small nicks were cut at the internal radius ends.

The bonnet was marked, cut and offered up and everything taped into position. I know it was only cardboard but it did look bl##dy COOL.

The cardboard panels were all removed and each one in turn was laid out on the aluminium sheet, marked out and cut to size. The cardboard panels were moved around on the aluminium sheets to get the most economical use from them! I used an air nibbler to cut the alloy sheets and a hacksaw and files for the delicate work. All the edges were deburred with the deburring tool to protect the hands from cuts. The edges to be bent were clamped over a precision metal table to get perfect 90degree bends. The larger radius of each side of the Locost bonnet was formed around an old telegraph pole until I was satisfied with both the radius and the fit. Another example of using what you have around as a tool and for a purpose. The Locost rear panel was folded, clamped in position and formed around the rear section using a good plastic dead blow hammer.

This took a while to fit, But Remember, "the eye will tell"

Each edge of the Locost chassis where the panels would be fixed to, I run a line of clear silicon sealant before assembly, so when completed there would be no panel noise from vibration when running. The finished panels were marked out, drilled and pop riveted into position.

Now it was £93 well spent!