After the sides had been cut, bent and fixed in place (DS tape and nuts/bolts) - Next a trial fit with the sides in place:
I kept this tray symmetrical (except that the hole for the diff is offset). The wooden version has a deeper section on the offside as there's a bit more vertical room, but with aluminium..............
The next job was to mock up a cardboard template for the diff housing.
Many minutes of tinsnip work later:
Bending in progress:
Fitted - DS tape and nuts/bolts again. I reinforced the front edge with some L section aluminium (Wickes).
Finally this afternoon - I've glued some O section neopreme along the edges, which should prevent any leakage from underneath. On the rear edge you can make out one screw head, there are two screws into the rear frame, and on the front I've added a bracket and there are two nuts and bolts, one either side of the centreline, mainly to prevent rattles.
And here's the cover in place. The yellow 'rope' came from a torch.
This is not the end, because I need to finish off the underside, and line the tray with neoprene, so there will be a final instalment next week hopefully.
A word of warning though - unless you have steely resolve, and are competent in forming metal, don't attempt this at home. It looks easy but it's one of the hardest jobs I've done.
