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Contrary to what the factory might tell you, an elementary tool kit will not
be sufficient for you to complete this build (unless their idea of elementary
is different from mine.) Following is a list of tools I have found to be
useful during the build. I'll add more as I find a need for them.
- Screwdrivers - Short and long handle flat blade
- Allen (hex) wrenches - In metric sizes
- Box-end wrenches - Metric and standard sizes
- Crowbar - For unpacking the crate
- Hammer
- Socket wrench - You'll want a good assortment of standard and metric
sockets as well
- Rubber mallet - Useful for installing the suspension, among other things
- Steel punch - For locating the rivet holes in the aluminum panels
- Power drill - With cobalt bits, for drilling rivet holes. You may also
want a drill with a very short or angled head, for getting in to
tight areas. The full-size power drill I have was too large to get
some of the front bulkhead rivet holes, so I bought an air-powered angle
drill, where the drill body is at a 90 degree angle to the head.
- Jig saw - With a fine-tooth metal cutting blade, for cutting the aluminum
panels.
- Rivet gun - Hand or air-powered. I *strongly* recommend an air-powered
one.
- Die grinder - Get a fluted metal-cutting bit, preferably a cylindrical
one no less than 1/2" diameter. This won't gum up like the grinding
stones, and unlike the pointed cutting bits, it will be easier to
control when you have to make deep grinds. I use an air-powered die
grinder, but you may be able to get away with a Dremel tool.
- Metal nibbler - I use an air-powered metal nibbler to quickly remove
large irregularly-shaped areas from the aluminum skins. This is not
strictly a necessary tool though.
- Rulers - 12" and a meter stick are handy.
- A square
- Black permanent marker
- Synthetic grease - For suspension fittings
- A caulk gun - For the adhesive/sealant used to bond the panels
- A torque wrench - Rated up to around 80 lb-ft or so. You'll need to make
sure your sockets fit on it. I recommend the dial ones, rather than the
angle guage style. The dial ones are more expensive, but also more
precise.
- A plastic putty knife - For cleaning up sealant messes
- Brake cleaner
- WD-40
- A 2-ton hydraulic floor jack
- 2-ton sawhorses/build-up stands, OR 4 very sturdy racheting jack stands.
- A garage crawler - Handy if you have to work under the car
- A stool or rolling seat - Great when you are installing the wishbones
and brakes
- A metal deburring tool
- A telescoping magnetic retriever - Ever drop a nut down into a place
your fingers can't reach?
- Strong needle-nose pliers
- A wire brush and a normal brush
- A camera - Take pictures while you are doing your build, both for your
own records and for the enjoyment of others.
- A lug wrench/tire iron
- Shop cloths
- Waterless hand cleaner
- Shop glasses
- Hearing protection (if you use air-powered tools)
- Dust masks - Absolutely necessary when you grind aluminum!
- A hand file - Great for finishing up the cuts made with the die grinder.
- A razor knife/carpet knife - For unpacking stuff and general cutting needs
- A stapler - For repackaging things after inventory
- Silicone sealant - For anything which needs to be waterproofed. I use Marine GOOP.
Remember, don't buy cheap hand tools. Get good wrenches, socket sets and
screwdrivers. Cheap tools won't last, they will strip screws and nuts and
generally don't end up really saving you anything. Spend the extra money
to do it right.