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Old 04-30-2014, 10:59 AM   #271 (permalink)
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Quote:
Originally Posted by samwichse View Post
How are you isolating the aluminum from the steel to prevent galvanic corrosion of those screws?
IMHO I would use ECK
LINK:
Powerbrace Corrosion Kontrol

This is what "Peter Belt" and "Freight Liner" have been using from the factory for the last 20 some years.

I just attended a class where we are seeing this problem once again with some of the new cars that are using aluminum parts.

Ford has had a ton of problems on their Expedition aluminum hatch where the trim around the window makes contact. The factory sealant was not good enough to prevent this problem.

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Old 04-30-2014, 11:44 AM   #272 (permalink)
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My Honda insight suffers whereever the steel parts (brake lines are particularly bad) touch the AL. Some of the bolts do well... they have some kind of weird greenish coating on them which I understand is to prevent GC from happening, but it obviously had either a limited lifetime or didn't help if things are too wet.
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Old 04-30-2014, 01:21 PM   #273 (permalink)
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The mechanical attachment is the tabs and screws. I plan on painting the surface, then applying an adhesive caulk between the aluminum and the frame.

Front pan 12 screws
Main floor 15 screws
rear pan 12 screws

All tabs tig welded to the frame.

Each attaching point has enough strength to hold the whole vehicle in the air.

Corrosion is not nearly as big an issue as it is in northern areas. Each panel will be removeable if necessary with a #3 Plillips and an electric drill, could be cordless.

I'll paint the final assemblies with rustoleum which will also seve as a thread locker for the speed nuts, without making it too hard to remove and reinstall the panels.

The inside of all panels will be sound deadened and insulated. This thing is going to be quiet and completely roadworthy and weather potected.

Picked up some 6X1 hex (4MM) countersunk stainless screws for the side panels, which will be either sheet stainless or aluminum, around 24 gauge.

All present tab sdrilled and speed nutted with screws in place, did the front 6 today.

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Old 05-02-2014, 02:47 PM   #274 (permalink)
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Picked up 3 sheets of 24 gauge (about .026 thou) stainless sheet metal, 3X8 feet. Cut in half each panel will go on the sides between the parallel frame rails,which are exactly 18 inches apart. The sheets are coated on one side with a white surface. Should even save me any painting and they will probably be covered with graphics anyway.

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Old 05-17-2014, 12:34 PM   #275 (permalink)
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Front panel and sides installed, windshield mocked up in place.

regards
Mech
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Old 05-17-2014, 12:41 PM   #276 (permalink)
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WOW

- Amazing -

Your going to get famous with this project / car

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Reminds me of the 1930's dymaxium
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Old 05-17-2014, 12:41 PM   #277 (permalink)
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Looking very nice. Can almost see the finish from here.
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Old 05-17-2014, 12:43 PM   #278 (permalink)
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Here you can see the front wheels with the steering turned as far as it can go to the right. The steering stops are adjustable. I have them set so the wheels go as far as they can without hitting the ends of the trailing arm mounts. Front skirts will not have to extend far past the curvature of the body and should not significantly affect the aero of the vehicle. I plant to teardrop the rear into the sides of the body.

regards
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Old 05-17-2014, 12:48 PM   #279 (permalink)
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Old 05-17-2014, 12:51 PM   #280 (permalink)
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The sad part is that you will always have ignorant people second-guessing what will be one of the best-designed vehicles ever created. This thing is beautiful and still far from finished.

Great job! Good luck!

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