I decided to go a different route, for part of the bodywork anyway. The side panels (the main ones on either side of the engine compartment, from the lower firewall to the front suspension) are going to be removable panels, secured with Dzus fasteners.
The reason for that is because these cars are small, engine compartments are tight, and some of the fairly common maintenance items may be hard to do without removable panels. In my example, there is simply no access to the oil filter unless you either have a hoist or a removable right side panel. Access to the battery, starter, etc. are similarly restricted, so the removable panels will be a boon. Once those panels & the hood are off, it's all wide open....all in about a minute or two.
My lower firewall panels are 20 gauge steel, welded to the frame. The upper horizontal & vertical panels (1/8" aluminum) are bolted to the scuttle via tabs welded to the scuttle frame. This allows removal for access to the back of the gauges, pedals, steering column, etc.
You see, "Murphy" is, and has always been, my co-pilot. The instant that I permanently attach something is the time that I discover I need to take it off again, usually even before the welds cool. As a result, my "mantra" throughout my build has been "ACCESS!!!". It's been a lot more work to do it this way, but allowing access to virtually everything reduces the likelihood and/or frequency of access required (sort of the corollary of the "Murphy" factor - like taking rain gear and umbrellas to the beach on a sunny day).\
I will be attaching my aluminum rear & cockpit side panels with rivets, because I don't really see a viable alternative. I know, they can be also attached with structural adhesive, but if I do that, they can NEVER be removed, for any reason. My buddy has attached his panels with bolts, rivets, AND structural adhesive (and the cost of doing so was enormous). Of course, he has the "luck of the Irish" and, chances are, the need to remove anything will never occur. Not so, me, of course. I am the person the statement "If it weren't for bad luck, he'd have no luck at all!" was created.
Wherever possible, I've used welded-on tabs with captured nuts, and bolts for attaching stuff. I don't like the idea of drilling hundreds of holes in my otherwise airtight/watertight frame.
_________________ Scratch building, at continental-drift speed, a custom McSoreley-design framed, dual-Weber 45DCOE carburated, Zetec-engined, ridiculously fast money pit. http://zetec7.webs.com/
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