Skin replacement

[greg176]

Having enough good weather on long weekend to do front panel.Just got panel off Saturday morning and it started to pour rain.Finished front belly panels saturday and spent Sunday fitting and drilling new front panel.We'll rivet on panel tomorrow.Phots are of opening and panel held on with two cleco's.

[uwe]

This is starting to look really good!

[Ken J]

Ahh it looks pretty sunny to me...

VERY nice work - was the front originally one piece, I've never seen that before, all the ones I've seen are three pieces. I noticed you did the back in one piece also.

You are inspiring to me - I'm getting the courage to do it too - next project after the new floor.

Ken

[Ken J]

Did you ever get your angle drill?

[greg176]

Yes the front and back were originally one piece.The front is 12' 2" long and the back about 14' long so the roll of aluminum from Airpartsinc helps.The front and back are easier to do than the side as the curve gives the sheet some stiffness.I'm hoping a sheet of 040" will show up before I do the curb side.I have not got an angle drill yet.I am back to work and can borrow one for a couple of days at a time when I need it.For this panel I can pick up the holes from the side panels.

[uwe]

Such a clean look! Too bad you have to put rivets in it. It looks very clean this way.

[greg176]

Well we had a long day today but the panel is riveted on.My wife did a great job again.We used up two tubes of Sikaflex on this one (one for the panel and one to cover me)

[Over59]

Very very nice.. Skill does show.... Is that a 59 overlander?

[Tinsel Loaf]

Congratulations on such a wonderful looking job. Truly professional.

[JohnG]

Again, your work looks great.
One question since I never saw the beginning photos. Why have you have to replace so much skin?

[greg176]

Thanks for words of encouragement a big help as I am only half way there.

Over59 It is a 61 Overlander.

John The photos are on page 2 of this thread.That last panel was badly scraped on both sides,had a lot of extra holes,a few deep dents and was badly corroded on the front face by a battery spill.The aft panel had a large badly made door in it and the sides of it were stretched by being towed with no floor.The sides were stretched and full of deep scratches.I will also replace the roof as it was replaced by the PO without any sealant,is badly corroded and I believe to be condition O aluminum.
I worked for many days trying to polish those panels to salvage them and now feel it is easier to replace them.

[markdoane]

Two more good things about putting on new panels:
1. They shine up quicker
2. You don't need to line up all the old rivet holes.

Greg, your project looks absolutely great!

[greg176]

Started on front half of roof skin this week.Drilled out rivets and covered up with tape before going to work.Today weather forecast was for rain by noon so got started early and pulled off roof then taped on new panel just before rain started.No stress!

[till]

OK, Stupid question....

Is the roof sapose to be one piece of aluminum?? Mine is one piece......
Just want to know if the older units are different.