Over the course of the week I’d been mulling over in the back of my mind how I would actual refit the battery box using the correct dome head rivets. The official instructions on how to “close” a dome head rivet didn’t offer much encouragement as I am bereft of six arms.

Some sort of air hammer would be useful but any online order would take two weeks to get here. So, thoughts of how I fit all of this back together were returned to the back of my mind where it fought for space with all the other stuff in there….

A fruitless visit this morning to the local hardware store to find some countersunk pop rivets (a fairly innocuous fixings) did yield an air hammer!!!! The kit of parts came with a number of chisels for doing everything except hammering with a parallel face…. I’d have to make one. On on….

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Air hammer and a selection of remorseless cutting instruments.
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We’ll use this one to make the parallel drift. It’s original purpose was to cut through sheet steel (or some such) and as I’ve never had to cut through sheet steel, I don’t feel bad about improving its design
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The hacksaw didn’t make much of a dent in it. Must be high carbon steel…. The angle grinder made light work of it.
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New parallel drift 🙂

Apparently I can upload videos too. Yay….

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Meanwhile… back in the garden, the component parts get themselves lined up (I hope you note the grass has been cut)
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Dry fit of the battery box and end piece
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Marking out the 4 spot weld holes
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Everything looks aligned at the rear
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New end panel with new holes corresponding with those on the old end panel
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Here we go…. first rivet replacing the old spot weld
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Air hammer ready to go
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Thats what we’re looking for. There’s some damage to the paint but the inside of the battery box will be lined with Dynamat, so its no problem.
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All 4 spot welds replaced
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Next is the bottom of the end panel to battery box. First the holes need to be drilled out.
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There was (about) a 3mm gap between the inside face of the seat and the new battery box. This gap needs to be closed for the rivets to work properly, so a few judiciously placed M4 bolt were temporarily installed  in every other hole.
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Job done
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Battery box and end panel installed
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Seat box offered up to the chassis….. The subframe is missing but you get the idea
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… and most importantly of all… a bullet box fits in the battery well. The tools have to live somewhere.
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Seat box rubbed back for the final time ready for the last coat of paint
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Finished product. The paint has orange peeled a little due to the temperature but I can live with that