IaM-Ray posted:Looks very nice how are you finding the build process so far? Measure 5 times cut once
I reply on watching the build videos, I can run them back as needed to confirm what I am doing and check the next step as a back up before I do the prior step. Only head scratching issue was how to get the gas door assembly off the fender ( it gets reused) One screw , remove the cap and give it a good hard yank) Every aluminum panel and brace hole is precise they are a small 1/16th pierce made by the CNC laser cutting system, all I had to do is open them up to 3 /16 or 5/16".
Every part was cut perfect and fit exactly. The important area to check during assembly is the tailgate vertical gap measurement. I am adding two aluminum 1" x 1"x 14" angles at the fender to tailgate area to give it additional strength with Panel Bond. The assembly videos show Panel Bond and countersunk rivets which get skim coated. I know better as over time, rivets tend to sink a hair and in the right light you can barely see the slight divots. I'll bond and temp screw all the FG panels in place then when cured I'll remove the screws, taper the screw holes and fill them in. FYI, 3M Panel Bond is stronger than the actual sheet metal and FG it is designed to hold together .