Most of the manufactured Sevens, like the Stalker or even the Caterhams use an aluminum floor. I saw no reason to weld in steel for mine so I bought 16 gauge hardened aluminum and used that.
I cut it with these sheers I got from Harbor freight.
I drilled holes and kept things lined up with clecos. I used screws like for this purpose along with a polyurethane adhesive to attach the panels. It seems to work well for the stalker guys.
The chassis is painted and I've got the floors in. Then I got the bulkhead cut and installed.
I've been dreaming of this for a long time now. It feels to get this far.
I got the firewall and related panels cut in the aluminum and installed then I made paper patterns for the sides and cut them out. I used clecos to attach it for test fits and trimming.
Here it is riveted in place. It sticks up above the side rail to be wrapped around.
Here's a shot of the wrap both inside and out. I'm using a soft grade .05 thickness aluminum. Just light of 1/16" thick. It had been both easy to work and thick enough to stay put.
June 3 2009
This is my paper patterns for the rear quarter panels.
This is some months later, close to a year, maybe. May/June 2009
A belated shot of the firewall. I'll make a box for the center section for the battery. It will hang down just on top of the transmission. I'll mount the coils and remote reservoirs about where they are sitting now.
Cutting the pieces
Getting the pieces fit and bent around the frame. This went easier than I expected.
The back completed. Although this could have come out a bit better I thought it went well for the first time I ever did any aluminum work. I probably could have spent more money for sheet metal tools but I just don't know if I would ever use them again. I'll build a wood top for the "boot" with a locking door in it. It will have a drop edge that will cover all the top rivets. The camera really brings out all the, even tiny, imperfections in the metal but I think it will look pretty good in the end.
