Rear Panel - Part 1

Well, the time has come... I have to bite the bullet and give consideration to fitting what most builders consider the hardest piece of the zero build - forming and fitting the rear panel.

It looks daunting when you see the single largest piece of steel flat on the floor and I profess to have spent alot of time reading fellow build blogs, studying photos and basically building up the courage to jump in and get the panel formed.

After reading the various blogs and techniques I also asked the factory how they did it more to confirm some understanding but I guess to see if they had any secret alchemy they used to create this major panel.

Truth be told.. the GBS way of of construction was what I ultimately followed and I will share with you below the technique they used.

So one Saturday set aside with no distractions, plenty of space time to build a rear panel:

• I covered the patio table with some old carpet/towels and sat the rear panel onto the table top - back down. the panel is quite weak so make sure it is evenly supported.
• First thing, do not try and roll the side at this point, you need to do some prep work before some bends are put into the panel. 
• The tabs along the top edge and sides of the under section need bending 90deg, the top edge toward the front of the car, the under section upward. Precision doing this will help later. bend from the bottom of the slots.
• locate the hole in the last under section tab, and make sure you have an appropriate bolt to fit, the hole is roughly cut at 6mm and will need filing out. Locate the corresponding hole in the outer wings, (the bits that will come around to form the sides, and do the same as above).
• now, without trying to roll anything, bring the two holes together on each side and nut and bolt.
• The rough rear panel shape is now formed.
• keeping the the under section straight, a straight edge and marker line is a good idea, starting with the tab you have just bolted, push the sides and tab together drill and rivet. This is quite challenging if you are on your own so a spare pair of hands is useful!
• continue down the under panel both sides until all BUT the last tab are secured, do not drill this it will be visible - its not covered by the wing.
• the rear panel should now sit on the under section
• now the top panel hoop, which is even more flimsy than the rear panel - be careful with this piece it is visible so any kinks/damage will be seen
• find the centre of the rear panel and the hoop, position rear and hoop together with bolts.
• align the hoop to rear panel matching the center marks so that rear panel is slightly proud of the hoop
• clamp the parts together at each point you drill and and secure with Cleco's, continue across the rear.
• manipulate the sides so that the side radius matches the hoop radius, again the sides should be slightly proud of the hoop. Again a spare pair of hands is useful otherwise use some quick clamps to hold in position whilst you drill and Cleco

Doing the above will form the panel - as the pictures below I hope prove..

The whole process should not be rushed and I spent a good part of the day doing this task - overall pleased with the result and compared to the scuttle on reflection, I think the rear panel is easier to do - the instructions from GBS were spot on and I would recommend this method over other methods which fellow builders have adopted - each to their own, they have all achieved an end result.