curbside replacement panel

[roostream]

I've got a scrape, or rather more of a gouge on my lower curbside panel of my 68 Tradewind, I'm completely comfortable replacing it and have all the tools necessary to do so. My question has to do with making an identical replacement panel. I'll use my damaged panel as a template to cut a new piece, but my question is, should I predrill all my holes using the damaged panel as a template, or should I only drill a handful and put it up with cleco's and drill the rest once it is in place?

Looking for some guidance from some rivet masters.

Thanks

[vintagemotor]

I have done this several ways;
1. Drill only a few "pilot" holes to get the sheet hung then drill and cleco all the rest. This is my recommendation.
2. Lay the old sheet on top of the new on a bench and carefully drill through the new sheet. This is fine as long as everything is 2D, as we know AS are not 2D. I do not recommend this method.
3. Make a paper template of the old sheet and tape it over the new sheet and carefully drill all of the holes. Now we are 3D and this works well but very time consuming to get it right. This is reserved for compound radius and very damaged panels.

To answer your question, I would recommend option 1, take your time and have several people there to help you hold the sheet in the perfect position before you rivet. A lot of people (myself included) are now using #6,#8, sheet metal screws instead of clecos, just turn your clutch way down so they don't rip through the Al.

Good luck!

[Shacksman]

I know that trailer! What I do is carefully lay the old panel on top of the new piece. Start near the centre of the length drill hole and use a cleco move both ways from centre drilling and using clecos so the holes stay aligned. If you cleco, say every other hole, the 2 sheets will come out identical and the holes will line up on the trailer. When hanging the new sheet do the same, start in the centre and move both ways with clecos every other hole then rivet the empty holes. Takes some time, and lots of clecos, but works out pretty good. When hanging you will have to drill out the trailer holes to match the 5/32' rivets as the originals were 1/8'.

[Bubba L]

Seems like you would consider the lap. The top of the lower panel should slide under the panel above and turn under at the banana wrap. So, the two sides I would pre-drill overlaying the old sheet. The top slides under the sheet above, so follow the existing holes when you have it in place. With the ribs and stringers, I would make new holes. This is all assuming you’re removing the inside skins and bucking everything back with 5/32 rivets. Good luck, Bubba

[roostream]

Thanks Doug, going to pick up some aluminium from Aircraft Spruce on Saturday - I hope to be tackling the replacement in October sometime.