Blind Mule – 999 (my dragster’s name) was my first time working with sheet metal in 2011. I just went to arts & crafts store and got 10 sheets of large poster board, it bends real easy and was 50 cents a sheet. I just cut and taped the poster board to the chassis until I liked what I saw. I got the poster board in a few colors, I wouldn’t do that again. I would just use white poster board as it is the least expensive and provides the easiest contrast on your eyes, it reflects light well. Don’t be in a hurry here, as you think on it, you will change your mind. Some changes because you’ll come to conclusion it’s easier to make aluminum do this way versus that way….. or due to dzus fastener locations. Having your buddies come over for a looksee, that’ll make you modify your cardboard panels a lot more : )
For the aluminum, I got 0.040 thickness, size was 4x8 feet, one sheet cost $70.00 in 2011. I thought I would make a few mistakes learning, and at $70.00 a sheet, pretty cheap in case I have to redo my panels a few times. Well, I lucked out, went slow, real slow and my first set of panels, I was happy with. I found out for the flat panels, it is okay to cut them to exact size the first time. I left extra just in case to trim, and found out was unnecessary and just made twice as much work. Buy one of those electric shears, they work great. I just practiced a couple long and curvy cuts and was ready to go.
When you go buy and pick up your panels, take 2 sheets of plywood so you can sandwich the aluminum panel between for loading in back of your truck. If you just set the aluminum panel back there, and drive on the freeway, it will blow around and get damaged. The 0.040 gets dents and scratches real easy. It comes with a protective plastic film on it, just be careful, the dent or scratch will end up right where you don’t want it……
Glenn - Roo Man's bodywork is "First Class." I enjoy seeing cars in that state of finish... during construction more than the final product : ) DF