Where to cut? Metal inner fender content.

If you have followed Project D2D, I have a problem. I can't drill the last two holes for my heater box delete plate, as seen below:

So I ask, do I trim just enough to get it work or do I trim to one of these lines?

I asked a buddy of mine and his is like this:

What does everyone else say and think?

Simpilify and add lightness?

Can you get in there with a right angle drill and a stubby drill bit?

A quick pop with a plasma might also get in there, though not the cleanest of holes.

How about a little angle iron held in place with the other screws and keeping that corner down?

matthewmcl said:

A quick pop with a plasma might also get in there, though not the cleanest of holes.

How about a little angle iron held in place with the other screws and keeping that corner down?

Don't have a plasma cutter. No screws, only rivets.

Appleseed said:

Can you get in there with a right angle drill and a stubby drill bit?

No. Already did that to the other 4 holes. Physically the drill and bit are too big to fit into that space.

Is this a piece you will need to remove for some reason? If not, why not panel bond it in?

I would try to keep the inner fender as intact as possible. That radius gives you a lot of rigidity.

jgrewe said:

Is this a piece you will need to remove for some reason? If not, why not panel bond it in?

I would try to keep the inner fender as intact as possible. That radius gives you a lot of rigidity.

Because it will be fire caulked on the backside. I'm just not a fan of panel bond for this or I'd use it.

Its a body on frame, I'm not so sure that strength is in play here. Inner fender is is more of a placeholder/alignment for the radiator support, plastic fender liner and outer fender.

How about a long drill bit? Run it through both panels. (Copper colored clecos= 1/8" right?) Orange box store has them 18" long but you could probably find a shorter one for a bit cheaper somewhere.

I've used the 3M fire caulk in other places, awesome stuff. That panel will be a puddle by the time it stops doing its job.

edit: Can you even get your rivet gun in there if you do get the holes drilled?

You mentioned it in your thread but I'd be tempted to try from the inside after some careful measuring. Although I don't know what it looks like in there, if you can get the rivet done from the inside the only negative is that you'll have two facing the opposite way(?).

Otherwise, I think I'd just make myself enough room by trimming a bit and if it bothers you later, just weld the piece back in. 

I would cut a slot in the firewall tin  where you want the rivets. Use a rivet washer on the backside and you will be fine.  But I wonder how you are going to squeeze rivets if you cant get a drill in there? Maybe some number 19 machine screws for those locations? 

If you must have a hole, then do the slot thing and with an aluminum or brass nail in place weld the slot up to leave a hole.

Or, these things are a thing and might do the job.

In reply to NOHOME :

In reply to Ranger50 :

Looks like you already got it done.

So what worked?

In reply to NOHOME :

Initially, I just cut out enough to drill the holes and install the clecos.... Then I removed the rusty battery tray then kinda went f this and cut the rest out.

So much room for activities!