Props to an awesome build and really enjoyed the videos. Keep em coming!
Are you unhappy with your panel supplier? Knowing who can supply the clad honeycomb panels would be a big help on my project.Next, we installed the Honeycomb Composite panels, I can not recommend any manufactures, sorry.
All mating surfaces were scuffed, primed with Sika 206 and then bonded using SikaFlex 252.
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We used small strips of a stiff rubber gasket material with 2 sided adhesive to act as a 1mm spacer so that when the butterfly rivets were installed it did not press all the adhesive out. Here Kara is poping rivets like a mad person...
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The rivets are not needed for the structure, but they are the perfect clamp to hold the aluminum tight to the panels as the Sika cures.
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I installed the absolute brightest, most densely populated LED strips inside of 45-degree aluminum extrusions with nice diffusers so I could see what I was doing as I added the last of the panels.
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The videos for this stage is here:
Thanks! I drew a bulk of the CAD myself, although I had help from several ME friends who work in the industry. I did get ahold of the CAD model from Ford, but it was 8 gigs and when opened it brought my high-end system to it's knees. So I just used the body panels you can see there and omitted most everything else. But as you can see, the Ford Model is very detailed:
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