Right then chaps I managed to find enough time. Tested and ready for Cornwall.
Holes enlarged and temporarily edged.
I tried the Dremel to enlarge the holes, but it was no quicker than a hand file and harder to control.
If you need to file the edges of a hole, use a pile of masking tape rolls as a stand and all the filings drop down the middle.
Test fitted and found to be OK. i.e. dipstick pulls out, and oil filler cap pulls out. The oil filler cap on the GDI is a tight fit and a fiddle to remove at the best of times.
I've fitted a collar to the oil cap. This is rubber sheeting. The inner edge is chamfered so that the cap will secure properly.
UPDATE: I eventually removed the rubber collar.It was OK without it.
Next a light dusting of etch primer and satin black.
Then remove the protective film......
....and test fit. At this point I'd planned to edge the whole thing with the same profile as the two access holes, but I've decided it looks OK as it is..................
This is the air gap..........
So we'll see how it performs.
UPDATE: Very good performance in monsoon conditions. This modification is well worth doing.
