Brand new segment: predrilled holes not lining up!

[66replica]

Hi all,

I'm attempting to replace one of the upper end segments on my '78. Here's a rundown of what has happened so far:

Put trailer on jackstands. Leveled on both axis.
Drilled out end segment rivets
Removed old end segment
Using a new Airstream segment (#21), attempted to line up the bottom predrilled holes before trimming.

Unfortunately, after about an hour of struggle, I can only get 1/2 the clecos in. The front curve will not line up. They're off such that I can't see the underlying hole. The curve matches, though. Here's some photos. Any advice? I've tried moving the panel around, shifting it, etc. This is the best I've got it thus far.

[66replica]

Update: I placed the new segment inside the original and lined the curves up. While some of the holes do match, there are quite a few that are off completely and some that are slightly off. Is this normal?

[desertair27]

Originally Posted by 66replica

Update: I placed the new segment inside the original and lined the curves up. While some of the holes do match, there are quite a few that are off completely and some that are slightly off. Is this normal?

I figured the holes were punched on panels from that era and should line up. You may want to contact some experts here like Frank aka 62overlander or Lance aka Top. They will know what to do but it sounds like you may have drill some new holes.
Good luck
Mike

[overlander63]

The holes will almost certainly not line up. You're lucky some of them did. Just drill new holes into the segment under the new one, using the holes in the new segment, and use them.

[66replica]

Originally Posted by overlander63

The holes will almost certainly not line up. You're lucky some of them did. Just drill new holes into the segment under the new one, using the holes in the new segment, and use them.

Good to hear. When the holes are marginally close (I can see some but not all of the diameter of the hole underneath through the new hole), is it ok to drill and rivet there? I'm using Olympics, if it makes a difference.

Thanks for the replies!

[Belegedhel]

So, when you say "predrilled holes," were these holes drilled at the factory, or holes that you drilled to match the original panel? Regardless, I have had poor luck getting holes to line up again, even an original part to another original part. Redrill the holes if you have to and don't sweat it too much. Olympic rivets may help to compensate for the multiple/wallowed out holes--again, I wouldn't sweat too much about it. Just put the whole thing together "wet" with plenty of vulkem in the joint, and between the glue/sealant and the rivets, it will all stay together just fine.

good luck!

[66replica]

The bottom side of the panel came predrilled by Airstream. This is the side that isn't overlapped by another panel.