Sheet metal work to install the fuel tank #2

This weekend I repaired the trunk floor around the fuel tank using the formed sheet metal I made last week.

First of all I made the holes on the formed sheet metal for riveting. I emphasized sturdiness rather than a smarter appearance.

I used steel rivets with 4mm diameter.

Aluminum & steel rivet or stainless rivet was more popular. But to avoid the erosion I looked for the all steel rivet.

I placed the formed sheet metal on the part to be reinforced and made the holes at the same position on body side.

Then, the remained POR-15 tank sealer was painted on the body to be repaired and both sides of the formed sheet metal. POR-15 hardened rigidly after drying, so it would be very effective for both the rust prevention and the reinforcement.

The remaining POR-15 was wrapped in a plastic film to be shielded from the air, but the surface had already begun to harden. But the inside was still soft and usable.

The formed sheet metal painted with the tank sealer was riveted on the body.

As a finish the tank sealer was painted on the rivets and stuffed in the small gap between the formed sheet metal and body.

I guess that its appearance was not very smart, but strong enough.

I also painted some other parts with remained sealer to utilize it as much as possible (it would be completely hardened in next days).

(My original blog was written on 28th Sep. 2008)

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Tip to repair rubber parts

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The day my "onboro ALFA" would revive

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