The instructions from Van’s seem backwards. Instead of temporarily installing all the parts and then match drilling, the manual instructs you to assemble the parts before fitting everything together. I think this is a recipe for poorly aligned parts. Plus, this means I’ll have to match drill and dimple the fwd channels after finishing. Not ideal.
I clecoed the partially assembled center sub panel with the remainder of the front deck. This is one of my favorite parts of the project. It’s so cool seeing the individual pieces come together into the larger structure.
I clecoed the top skip to the front deck skeleton so the fwd channels could be match drilled. This was actually pretty tough for the F-644-L/-R Channels.
I originally tried to just match drill the holes, but that was too difficult. You can see where my drill missed the centerline on the forward end of the bracket. Instead I just marked the first hole location and drilled it without the help of the skin.
Van’s tell you to drill the F-743B Angle to the fwd channel before the channel goes into the vehicle. This would be problematic because the spacing to the firewall will be incorrect. Instead, I taped the angle to the channel and shifted it around so that it was properly located against the channel and the firewall. I used an extended drill bit to hit those holes.
