I cut out a floor section last night and glued along one side length with poly cement. I also noticed that one side/cab casting joint was a bit "off", the lower side being a bit too proud near its base and the whole thing at a slight angle. So this morning I unglued it, which was messy and difficult, although looking on the bright side I don't envisage the body coming apart at these joints in service(!) I then chivvied everything and have just stuck it back together and also run poly cement along the base of the side, there is a slightly larger gap between casting and side than there was but that can be filled.
Here it all is with various weights in place to hold the sides as tightly as possible to the floor while the poly cement goes off, hopefully safe to handle by tonight.
The mark on the side is where superglue ran between the side and a piece of plastikard that I was using when I clamped it together, thank Gawd I thought about the possibility and removed it before the glue had fully cured
I'm pretty confident about cleaning this up. In any event all four of these joints will need filling and finishing and it may well be that there will be some evidence of a joint when it is finished but I figure that'll be a small price to pay for having created the monster in the first place.
So assuming I'm happy with the overall shape etc I reckon that tonight will see the start of flooding the joints with epoxy from the inside, which will strengthen the joint and firm up the thin side sections to avoid flexing when I start filling and sanding.
It will also make sense to try and make a roof section in the fairly near future, which will need to support the body side top edges along their lengths. This will hopefully ensure the whole thing stays the right shape as all the glues dry off and I tack other bits on to to it.
So still travelling hopefully, roof challenge looming...
Simon