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Old 03-30-2016, 02:59 PM   #68 (permalink)
3-Wheeler
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Join Date: Dec 2008
Location: Southern WI
Posts: 829

AlienMobile - '00 Honda Insight
Team Honda
90 day: 80.05 mpg (US)
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Quote:
Originally Posted by brucepick View Post
This project shows amazing craftsmanship. Thank you.

How did you attach the panels along the sides - at the rocker panels?
Hi Bruce,

I originally used mild steel fasteners in all locations, and they work fine, until driven in the winter with salt on the road.

Since then, I switched to stainless fasteners where possible.

The rocker panels still have mild steel plaster board screws. Each year, I have to pull these out, and either replace with new, or coat them with anti-seize paste.

Fastener rust is the biggest issue I have with the underbody panels and tail.

Speaking of rust, part of tail is held on with 1/4-20 x 4in bolts, and some of these rusted enough over the years, to break off when attempting to tighten slightly. I had to remove the tail to replace all the mild steel bolts with stainless.

Hopefully this summer I will get the chance to completely sand down the tail to get all the lumps out and then repaint it with a color that matches the car. The lumps came from using light-weight spackling as filler, and expanded when the sun heated up the surface in the summer.

Jim.

Last edited by 3-Wheeler; 03-30-2016 at 03:04 PM..
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