Aircraft construction is perfect for early style hot rods for several reasons, not the least of which is aesthetics. Fighter planes and race cars are spare creatures: what doesn't go into them doesn't require power to move around. As a result they look lean and mean.
But minimalist machines needn't forego creature comforts; they just have to reflect that less-is-more philosophy. For example, Frank Wallic said he figured that conventional carpet would look out of place in an interior that looked more like a cockpit. At the same time he said he needed something to keep his feet from sliding around on the slick floor. At least he needed a way to protect the varnished floorboards from abuse.
Frank Wallic cut two sheets...
Frank Wallic cut two sheets of 0.063-inch aluminum in the pad's overall dimensions and marked them both for rivet spacing.
Twist drills work but hole...
Twist drills work but hole punches like this Roper Whitney No. XX (the XX is the depth of the throat and the pressure it will develop) unit speed things along. Exact location still requires center-punching the locations, but these hole punches eliminate a lot of the time and tediousness.
So he drew upon the construction techniques he'd learned by making aircraft-style panels to whip up a set of very simple heel boards. He also took the project as an opportunity to use some real neat rubber matting that he found at Restoration Specialties and Supply.
Wallic offered three construction techniques: one with a riveted ring, another that folds over itself, and a simple non-riveted type. They vary in difficulty, but even the most involved style is within the grasp of anyone willing to invest themselves with a little creative effort and a few inexpensive tools.
Using the retaining ring once...
Using the retaining ring once again as a template, Wallic marked the Restoration Specialties rubber sheet with a white grease pencil (aka China marker). Ultimately he cut the rubber to exactly the same size as the ring.
Smooth rubber surfaces do...
Smooth rubber surfaces do not bond well, so Wallic scuffed the panel's backside with sandpaper.
He did the same to the aluminum...
He did the same to the aluminum panel, only with an abrasive pad.
Wallic prepped the Restoration...
Wallic prepped the Restoration Specialties rubber and the baseplate with standard-issue air-drying contact adhesive.
After letting both surfaces...
After letting both surfaces flash dry, he carefully united the panels and rolled out all bubbles to promote a good bond.
Wallic plotted the interior...
Wallic plotted the interior cut lines for the retaining ring. He cut most of the inside perimeter with snips, but to give them plenty of working room he punched out most of the metal from the panel.
Even when wielded carefully,...
Even when wielded carefully, snips can make a mess of a flat panel. Inexpensive nibblers, available at aircraft shops like Aircraft Spruce, make distortion-free cuts.
No matter the method, a cut...
No matter the method, a cut edge is never showworthy. As Wallic found out by lacerating his hand while trying to deburr a hole with a spindle sander, plain ol' flat files work pretty well-even if they are slower.
After filing the ring, Wallic...
After filing the ring, Wallic used the holes in it and the base as templates to drill the holes in the rubber.