My original plan was to fabricate all the aluminum bodywork, drill holes for rivets, then remove the panels and clean/prep/paint the chassis. Then I realized that water would get into the chassis tubes...since it's winter and I don't have an oven to dry out the chassis quickly, that's probably not a good thing.
So, plan B is to do everything but drill holes, then paint the chassis.
I'm using 0.040" 5052 (half hard) aluminum. I started on the left side panel. The brake I fabricated over the holidays works good, but has some limitations. I learned a few things along the way that will help with the second side. Currently there's a little waviness on the side panel (next to engine). I think I can work this out, but if not, fortunately the exhaust will help cover up any waves that remain.
Next was the rear panel. I bought an electric shear from Harbor Freight that works pretty good, but it's hard to cut a perfectly straight edge. For the rear panel I cut about 3/8" oversise using the shear, then cut to the exact size by hand. A few more panels with this method and I'll have forearms like popeye...
To finish up the rear section I need to wrap the panel over the chassis tubes, and clean up the transition to the side panels.
