You start by temporarily installing the
panel and trace around all the frame tubes.
Once completed, you remove the panel,
mark off your holes (usually about 2" apart), and then drill with a 1/8"
drill bit.
Again, install the panel temporarily.
I used some clamps, but you can use screws or drill a hole for a rivet
to hold it in place. The panel is now a template for drilling the holes
in the frame tubes. Again, a 1/8" drill bit is used. Remove the panel and
clean up any metal shavings.
Silicon all the frame tubes where the
panel will touch. The assembly manual says you can do this before drilling
the holes in the frame tubes, but then the metal shavings get mixed in
with the silicon. I think its worth the extra step in removing the panel
after the holes are drilled to clean up the shavings.
Mount the panel and put in lots of rivets.
I hear they make air rivet guns, but since I don't have a compressor, I'm
forced to do the old fashioned way. My hands are really tired. I started
off with a cheap rivet tool. That lasted about halfway through the drivers
cockpit floor. This necessitated an emergency trip to the hardware store
after first tool broke and silicon was drying on the halfway riveted panel.
The new, more expensive tool is working fine. The moral to the story is
don't buy cheap tools.
Here is the mostly completed trunk area.
The red and black post are the remote charging posts for the battery.
![]() |