Dakar Body off Restoration -
Had quite a large parts ordering session in order to complete the build:
Full sheet of 16 Gauge NS4 Ally -
Rustoleum Combicolor RAL 5017 TRAFFIC BLUE
Rustoleum Combicolor Satin Black
Cleko kit, Rivnuts, Stainless pop rivets and sikaflex from Car Builder Solutions
Wire, Crimps and slitted conduit from Vehicle Wiring Products
Starting with a whole sheet of NS4 ally, I created a template for the return edge in the rear wheel arch and then used a jigsaw to cut out the shape.
By clamping the panel to the bench, I hand folded the two angles on the panel (I used a protractor to measure the required angle on the car).
With the completion of the side panels, I realised that the battery boxes were in a very poor condition. This was due to the fact that I riveted bare unpainted steel together (due to my impatience at the time to get the car finished). So lesson was learnt there. I flattened the old boxes with a hammer to create the templates for the new ones.
Unfortunately I only had 16 gauge steel available -
Once complete I sent them off to Milton Keynes Powder Coaters (Alpha Metal Coating) and had the coated in RAL5017 powder. I also painted the chassis as I have always hated the grey colour.
The original kit has fibreglass arches -
In the second picture you can see my new tool; It’s a digital protractor -
A little more work to make some end caps
3mm checker for the floor, more powder coating and were done..