Mac - Thanks again for your kind offer.
Unfortunately, I need to do the coating in two stages around the bonding of the body shell (underside 'before' & inside 'after').
By doing the underside first, I'll have a better understanding of the roller vs. brush finish for the inside.
a big scary monster - Thanks for taking the time to join the forum to post your message.
I have always been happy for people who know more than me to make suggestions for my build.
So I'll have a look into the stone chip stuff as I know others have used it on their builds.
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Another Busy Day - Part 1:
I made sure I got all my chores done before lunch so I could take advantage of the dry weather forecast for the afternoon.
First job was to remove the body shell and then the rear framework so I could paint it.
There are a few bits left to paint on the frame, but I need this side to be dry, so I can flip it over.
With the framework out of the way I turned my attention back to the chassis.
I had bought a heavy duty 19mm drill bit which was marginally smaller than the crush tubes.
After expanding the 4 holes I'd already drilled in the chassis, I switched to a hand file for the final bit.
This gave me as close to a friction fit as my manual tools (& skills) would allow & all 4 tubes were in.
I marked the tubes and cleaned up the metal where I was going to weld them.
I also cleaned up the holes on the chassis & it was nice to see shiny metal under the paint.
As the rolling chassis is parked on a sloping drive, it is not easy to see what is straight.
So I used a "L" shaped ruler to keep the tube perpendicular to the chassis when I was welding it.
Don't ask me how, but I managed to blow apart the welding tip's shield.
Thankfully I had a spare, so soon all four tubes were welded into position.
Then I cut the tubes off with my angle grinder before cleaning up the top surface.
A quick spray of etch primer over the top completed stage one of this chassis mod.
I still need to drill 4 holes in the bottom rail of the chassis through these crush tubes.
At least by doing it this way mean I know the holes will line up.
End of Part 1....