Today I managed a bit more. The undertray.............
This is to stop dirt getting up onto the front of the engne. The only downside is that it makes it harder to get a jack on the cross tube, but with my lifting beam it's OK.
So first the template, which drew my attention to the offset.... laid on a sheet of 2mm aluminium.
First cut:
After a few test fits and after shaving the edges, now drilled and curved over the jack handle with a Thor hammer.
This is how it looks fitted:
The finish is a problem. Although one side is protected with a plastic film, it doesn't stay mint, and the other side is usually far from mint. So I just run the wire brush in the drill over it and cover it in swirls, which looks better than random scratches and lines.
It is shaped so that it slots in over the bottom chassis rails, which means a slight compromise on width. I could also be fitted under the chassis rails but doesn't look quite as tidy this way.
It's secured by using the towing eye bolts on the offside, and a single nut & bolt using the same holes on the nearside. At the rear I use a nut & bolt each side, penny washers top & bottom, and a cut penny washer to take up the gap. The penny washers then pinch the chassis flange and it doesn't need drilling.
