So I Need To Talk To A Sheet Metal Guy

the factory tolerances are like + or - 3/8 inch. which is huge when it comes to body tolerance. they all vary to some degree fit and finish weren't the main goal when they were new.

 

I have roughly 20- 24 clamps and diy clamping devices holding the panels in place.

 

That's the best way I use a lot of self tapping sheet metal screws after welding, the holes make good plug welds, after the screw comes out. Stand back a few feet and it always looks better

 

yes but I am not building a factory tub. I am building a DIY tub with a dash cowl and firewall and a little of the tunnel and all the rest is NEW repop or DIY metal. So how much or how little the original bodies varied has no bearing on what I am doing. Also I plan on building an insulated aluminum hard top It would be nice to have it sit square on the tub.

 

Then are you building from some kind of fixture or jig that allows precise symetrical measurements from master datum planes?

 

All I was doing was giving you some reference as to what it was new. I'm surprised that classic parts are not fitting well everything I've used from them was dead on. If you are fitting classic parts to other suppliers it's not a shock they don't line up.

 

The easy answer would be yes. I built a framed floor that measures within 1/16th of square and level from 3/4" x 1 1/2" .093 rectangular tubing. The wheel houses are made from a flat sheet of 16 gauge with the Original Wheel house tops/front welded to it. All reproduction metal is from Classic. All measurements used were taken from multiple tubs And yes some of my assembly was done over very accurate jigs to hold various pieces in correct alignment.

Maybe you guys need some photos











You can see the 30+ pages of my Build on the CJ-2A page here

A little project update on Chug A Lug

 

I withdraw the question!

 

SO problem in the OP solved as best it can. The Side Panel now lays against the Flange on the top of the Wheel housing at an acceptable level.

I came up with a new more vexing problem in that just ahead of the front of the Wheel Housing the side panel wanted to take a slight angle in towards the center of the Tub. To the point I actually had to brace the Side Panel at the door splice (angle of the body change) in order to get it to be square with the floor.

After moving a bunch of clamps around and seeing what changes it made I determined it was the L Brace that runs from the front side of the Wheel House to the Side Panel (the one just above the Fuel Fill pocket) I had left this brace on hoping it would make it a little easier to put the Side Panels on and save some grinding and welding.

Well not the case. How or why I don't know but that brace was at about a 86 degrees instead of 90 like it should be. SO I drilled out the spot welds and made a couple slices through the back side of the brace with my band saw and then pulled it out to 90 degrees. Since I cut on the back side the cuts closed up as I did this and then it was just a matter of some welding to fix the cuts. A few hammer wacks later and it fits pretty good.

Fingers were getting pretty cold so I'm going to give up for today. Plus the wife is not feeling well and me banging on the tub was not helping her nap.

I think unless I can invent another big problem tomorrow I can start the task of welding the left side sheet metal in place.