This was a part of the build that we were both unsure how it was going to go, It was the type of job that we kept putting off, there was always something else to do. When we actually started doing it it did not seem nearly as bad as we had expected.
The arch at the back was always the most worrying bit in the end it went really well.
A while ago when I was in Focus DIY shop they had a sale on power tools. I knew I did not need anything but things were really Cheap and I ender up buying a "Heat Gun" for £12, I knew it would come in handy and I was right.
First we cut a piece of white plastic tube down the centre section then using our new toy we heated up the pipe. Joey controlled the heat gun while I moulded the pipe into shape round the chassis curve I had my welding gloves on because the pipe was really hot.There does seem to be a optimum temperature that you have to get to so it bends nicely, if its too hot it gets all floppy but as you heat it up you can feel it getting mildly pliable it was at this point we moulded it onto the chassis. I then held it in position till it was cool enough for masking tape to hold it in place then left it for a while, then screwed it to the chassis using 3 self tappers.
Later on when the plastic had formed and cooled we glued the leatherret in position and pulled it tight round the edges then screwed the whole lot back on.
Then did the same with the side trimming.
So thats another Job out of the way!
Dad how are we going to fill these gaps?
Now was the time to make some sort of cover for the top of the footwells, first we cut out some cardboard jobs and taped them together then make the proper job out of Paxoline sheet.
This is what we have done with the passenger footwell, the carpetted panel on the left is screwed into place and the angled section in front slots into place at the forward end and it is held into place with a bungee cord. The top area we will leave open to allow access to the "Battery Isolation Switch".
Here is the little bracket in place that hold's the front panel in position..
And this is the drivers side with the heater duct fitted!
Further forward we wanted to make a panel up to cover the heater switch and pipes!
Here is this panel fully carpetted and trimmed. It is screwed into place with a Black plate between the two panels. In the event of one of the heater pipes bursting the panel will prevent any boiling water spraying on the drivers feet!
Here Joey is painting the inside of the panels, Makes it look nice.
See what I mean!
This is the drivers side before painting, the Black tape held the two panels together whilst the carpet Glue dried, then the whole thing was screwed in position.
