Click here to return to the home page.
Image of a road.
Who's Online Now
11 registered members (Robbie, lowebird, SCX358G, LightSpeed, Eddie Cairns, Chilliblu, Quicksilver, Scrambledsignals, B3MOG, Rovert, nick w), 88 guests, and 12 spiders.
Key: Admin, Global Mod, Mod
Top Posters(30 Days)
+8Rich 179
John V6 144
Hamwich 105
Newest Topics
Dave W. - looking forward for a second book!
by xc68anc. 17/11/19 08:47 PM
Windscreen Washer Tubing Under-Dash
by DaveW. 17/11/19 02:31 PM
spares
by rockabilly john. 17/11/19 01:18 PM
5 speeder parts wanted
by Phil Bleazey. 17/11/19 11:50 AM
New Roadster Spec at last.
by Quicksilver. 17/11/19 08:49 AM
One for Gary?
by Graham, G4FUJ. 17/11/19 08:44 AM
Morganeers at reifen.com Mainz
by xc68anc. 17/11/19 08:15 AM
Latest Photos
Exelent Morgan weather.
TM at Haynes
Keith's 4/4 resto
New 1913 Runabout replica in progress
Alloy spare wheel Cover
Newest Members
Farmer Giles, Mike pomfrett, JanBirger, esomann66, Hdnut
6760 Registered Users
Forum Statistics
Forums34
Topics36,624
Posts591,736
Members6,760
Most Online596
Nov 6th, 2019
Today's Birthdays
No Birthdays
Previous Thread
Next Thread
Print Thread
Page 1 of 5 1 2 3 4 5
The tool tray.............. #380190
26/07/16 07:41 PM
26/07/16 07:41 PM
Joined: Dec 2008
Posts: 17,889
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,889
South Yorkshire
Well, today I made a start on this. My first effort eight years ago was wholly wood, and made use of the extra depth available on the offside. It was fiddly to build, but has stood the test of time, but a 'never again' job. ooo

So three years ago when I needed another, having contemplated a wood & aluminium composite, I ended up making one essentially out of a single piece of aluminium, shaped like an aerofoil, and with two pieces added at the sides, and an aluminium box over the diff. It was about 85% OK, but really tested my ability with the tools I have available. It was a 'never again' job. ooo ooo

So faced with this again............ and the reason is very simple. Without extra capacity in the tool tray, all tools and other essentials end up under or behind the seats.

This is the standard set up. On the left is a circular recess which is said to be for a spare wheel nut.
There's a rectangle for a first aid kit and a wheelbrace shaped recess for if you have alloys.


At present, the standard supplied hammer is an aluminium Thor (on the left). My old No1 Thor with copper & leather hammer is on the right.


This is my tool roll, with the usual tools, plus some cable ties, wire, insulating tape (covering the MG badge), and a couple of extra nuts and bolts for the rack mountings. On the right are some spare junior hacksaw blades and a tyre pressure gauge.



With the tray out you can see the latest tank design. This tank is higher than the 2012 tank - which did present a small problem because I started work on Bumble, but more of that in a minute.


I measured the vertical clearance between the brake pipe union and the top of the tank.



Just under 2.25 inches - 5.5cm. That should be enough.



These two protruding nuts and bolt ends get in the way of the tool tray. There are two more on the other side.


Look closely - I decided to make this tool tray in two halves with a centre section riveted in place. This way I was able to make a start on Bumble and transfer the pieces onto the new car. I knew that it wouldn't be the same, but I hadn't reckoned on the fuel tank being higher! I got round this by curving the rear section to lose a bit of height. Interestingly the cut outs I had made on Bumble for the upper damper mounts were not big enough. There was a good half inch difference, so I've been busy with the tin snips. It was much easier to bend these halves using timber formers in the vice, than the huge single piece of aluminium in the Mk2 version. Although I had planned to build a slave body frame to make things easier, the differences meant that it was easier to do the fitting on the car, but taking real care swinging the pieces in and out.



The rear centre panel needed a cut out for the protruding sender/pick up. This is how it started.



Eventually I got a good fit. I'll need to make a cover.



This is the underside. Now riveted into a single piece. I've used double sided tape between the overlaps to seal it.



Final test fit of the day.



That's all for now. I have a few days at work and the Silverstone Classic, so it's on hold until next week.

It will need sides, covers for the damper top mounts and a diff cover. All very time consuming jobs, but so far I'm pleased how it's going.
You can see why the tool tray is so difficult to mass produce. Although Superform could easily bang them out, unless the trads can be standardised under the rear hatch, every one would need fettling before it would fit. To build tool trays as a cottage industry........... well, a good two days work and no guarantee it would fit without having access to the car.
thumbs



DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
Re: The tool tray.............. [Re: DaveW] #380254
26/07/16 10:34 PM
26/07/16 10:34 PM
Joined: Jul 2007
Posts: 14,095
Suffolk
John V6 Offline
Member of the Inner Circle
John V6  Offline
Member of the Inner Circle

Joined: Jul 2007
Posts: 14,095
Suffolk
Good work Dave. That tank really is different


JohnV6
2006 Indigo Blue Roadster S1
Re: The tool tray.............. [Re: DaveW] #380258
26/07/16 10:51 PM
26/07/16 10:51 PM
Joined: Jan 2012
Posts: 14,976
Perth, WA, Australia
Richard - Aus Offline
Member of the Inner Circle
Richard - Aus  Offline
Member of the Inner Circle

Joined: Jan 2012
Posts: 14,976
Perth, WA, Australia
Wonderful. When mine's back together I plan to build a "box" for behind the rear seat. You're providing inspiration!


Richard
1976 4/4 4 Seater
Re: The tool tray.............. [Re: DaveW] #380267
27/07/16 12:49 AM
27/07/16 12:49 AM
Joined: Feb 2016
Posts: 199
Singapore
Y
Yann Offline
L - Learner Plates On
Yann  Offline
L - Learner Plates On
Y

Joined: Feb 2016
Posts: 199
Singapore
Pretty good job,Dave two question will you make it movable ?? , second & last for the moment will you made some for separate tool and spare part (for example) smile smile

Re: The tool tray.............. [Re: DaveW] #380295
27/07/16 06:45 AM
27/07/16 06:45 AM
Joined: Dec 2008
Posts: 17,889
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,889
South Yorkshire
Yann - it will be screwed down and will have more than enough space for various tools. And lined with neoprene to stop rattles!


DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
Re: The tool tray.............. [Re: John V6] #380297
27/07/16 06:48 AM
27/07/16 06:48 AM
Joined: Dec 2008
Posts: 17,889
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,889
South Yorkshire
Originally Posted By John V6
Good work Dave. That tank really is different


It does beg the question John - will this tank fill above the level of the centre section. Or will that just be pockets of air......... thinking


DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
Re: The tool tray.............. [Re: DaveW] #380322
27/07/16 08:15 AM
27/07/16 08:15 AM
Joined: May 2012
Posts: 909
Sumerset
Rog Offline
Talk Morgan Regular
Rog  Offline
Talk Morgan Regular

Joined: May 2012
Posts: 909
Sumerset
Looking very nice Dave. I remember the last one, really impressed with your skill and tenacity.

It’s a job I want to tackle one day but I keep putting off because I know it’s not easy.

Last edited by Rog; 27/07/16 08:23 AM.

Roger
Plus 4
Re: The tool tray.............. [Re: DaveW] #380335
27/07/16 08:54 AM
27/07/16 08:54 AM
Joined: Aug 2015
Posts: 939
Worcester
GaB Offline
Talk Morgan Regular
GaB  Offline
Talk Morgan Regular

Joined: Aug 2015
Posts: 939
Worcester
This looks so good Dave, and so much better than the factory blister pack.
It even looks capable of storing most of the spares that everyone has been 'helping' me to pull together.

I could envisage a fabrication company doing production versions to make the space useful...


Glenn
2001 Blacktop 4/4 Corsa Red 'Archie'
Re: The tool tray.............. [Re: DaveW] #380428
27/07/16 05:18 PM
27/07/16 05:18 PM
Joined: May 2014
Posts: 3,545
Essex
Burgundymog Offline
Talk Morgan Addict
Burgundymog  Offline
Talk Morgan Addict

Joined: May 2014
Posts: 3,545
Essex
I pile all my tools plus a lightweight waterproof jacket and a car rug into the passenger side Hills Alive box. Job done.


Keith
2013 narrow bodied + 4 Ruby. Wolf performance Re-map suspension mods and K&N cone filter.
Re: The tool tray.............. [Re: DaveW] #381781
02/08/16 08:00 PM
02/08/16 08:00 PM
Joined: Dec 2008
Posts: 17,889
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,889
South Yorkshire
Well I've made good progress over the last couple of days but be in no doubt that this is a testing job using aluminium. The two section method is certainly easier than starting with a single sheet, but its still a huge challenge. It's almost complete but needs a bit of finishing off, so pictures will follow when I get ready to fit.
By the end it will have taken probably 30 hours graft, and it doesn't get any easier with practice! No way would this be good enough to sell..............
But it's good enough for me!


DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
Page 1 of 5 1 2 3 4 5

Moderated by  Aeroman, Simon 

Powered by UBB.threads™ PHP Forum Software 7.7.1