We finally got enough admin stuff out of the way to go hands on again today.  It is a good feeling to get a chunk of work done, and on top of everything, have it turn out really nice. The back panel used to have an access hatch, now it is a solid piece of .050 Alclad. We’re planning to extend the vertical rib that comes down  from the window frame, and add more vertical ribs behind the panel. I am pondering the need for rivets on the panel to the ribs, wondering if a few strong ribs alone would lend enough support. Where’s Kip when you need him? ( Kip Eagan is my metal and rivet mentor...aside from being a genuinely nice individual!) It just looks so clean without additional rivet lines.

The shell, with the old panel and access door removed. Note the vertical ribs stopping 8in shy of the c-channel.

The new rear panel, cut to size and pre-drilled.

It is a perfect sheet of .050 Alclad.

The sheet being test fitted. Just by itself, it is so much stronger than the .032  with the hatch opening in it that was there previously. We are going to extend the vertical ribs, barely visible in this picture, and tie them in to the C-channel. That should give substantial support to this part of the shell.

Here’s your humble narrator, molesting a pristine sheet of Alclad with some air powered shears. This would eventually become the curved rear shell section, sans the huge holes for lights and water heater.

Our air powered shears make anice clean cut, good enough for visible joints. The metal came covered with plastic foil, eliminating the need to run masking tape along the cut lines. The masking tape would prevent scratches to the metal by the shear’s movement. The plastic covering does the same.

The new rear panel and street side panel fitted and held in place by clekos. New Alclad is so perfect looking!

Same panel as seen from the inside.

Sheetholders are a life saver. Good Karma to the inventor of sheet holders!

And voila’, a new rear end for the Ambassador. Time to get ready for buck riveting the panels in place.

New metal, ready for riveting.

To be continued...