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Originally Posted by malconium
The problem with any coating I can think of is that it will mask the locations of the holes that the body panels attached to making it harder for me to find the original panel alignments for re-installation. Maybe this is not a serious issue but I am not sure. Any suggestions?
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My inner skins were pretty bad, I wanted to move things around, and I wanted consistent rivet spacing so I made new ones. It also seemed easier than trying to figure how to patch or hide holes I wouldn't use. I put 3/16 closed cell foam tape on the ribs before pop riveting them. The panels pulled up smoothly and it is not noticeable.
I considered what double drilling the ribs would do to strength and don't think it will be harmful. Pop rivets aren't all that strong and the ribs are thicker than the skin, any failure would be in one of them before the rib, most likely the rivet.
OTOH using the original skins I don't see why you couldn't pick up the holes. Use an awl or center punch to pierce the foam and line up the first hole, the others should be in alignment. The foam compresses very evenly and pretty thin, probably not enough to throw the other holes out of alignment even on the curves.
John