Unfortunately after some experimenting with the fitting of the rear hubs and spacer plates discovered there was a problem with one of the uprights. As can be seen in the picture below, the upright on the left has one of the driveshaft hub mounting holes too close to the upright's side plate. There isn't enough clearence for the bolt head:
After a bit of head stratching decided it was best to grind away the side plate a little to create the clearance needed - out came the Dremel with a sanding wheel attached - just the right size for the job:
The plan will be to get the uprights powder coated for the exposed metal should be sorted.
Floor panelling
Having got the floor panels back from powder coating and getting ready for sealing and riveting realised I hadn't read the build manual - doh! The build manual is fairly clear that the preference is for the large pop rivets to be used on these panels (for added strength if someone tries standing) - the panels had been drilled for the small pop rivets so out came the drill again.
A little time later, and with some unpaid help, all sorted. Also shown in the photo below are the front fillets which I think I'll get powder coated as part of a second batch of parts to be done:
Sealing the underside panels
Since getting the first panels back from powder coating I'd been waiting for improved temperatures but finally ran out of patience and warmed up the garage a bit. Sikaflex 221 datasheet indicates not to apply below 5*C or above 45*C (the latter wasn't going to be a problem). From talking to Steve at FSC the main issue is viscosity at low temperate making your arms ache. But based on the datasheet there is curing time which can be very long, even days.
Trialed the application and riveting approach on some scrap ali and square section first. Once happy, tube and garage warmed up, I got cracking and the sealant flowed nicely:
Having read a few build diaries decided to 'dip' the rivets in sealant to increase the sealing effect:
Finally also got to try out the loaned air powered riveting gun (thanks Gary from the Southern Area Tigers Owner's Club!) - did the job beautifully. One trick was to make sure the exhaust air from the gun didn't spray oil on the surfaces to be sealed (no aching arms though!):
The end result with the sealant curing nicely in the warmth:
Although the front fillet panels will be powder coated before fitting the chassis can now be turned upright for the final time and left that way (the front fillets will be fitted from underneath when available).
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