Here is a picture of the bottom of my car with the trays removed.
Pretty busy under there with little room to add 2 19 mm aluminium/ copper pipes for my A/W set up.
I could have run them outside the covers but dont like that idea, so the only option is to make new trays with a bump for the 2 pipes.
After thinking about this for a while i came up with this method.
Firstly to make moulds of the plastic trays , good idea but with one problem , they are flimsy and would move and wont mount in the right location( been there done that many years ago )
So what i did was to mount L shaped made brackets to all the mounting holes,
them bog pieces of MDF to these brackets and join them all together,
That way i would have a jig of the bottom of the car.
The trays would be mounted to this jig. This way there wont be any movement and all the locations would be spot on.
To simplify things i pop rivited 3 of the parts so as to make one part.
So the next step is to make the mould. I used 2 part epoxy and HEAVY carbon fibre. I laminated 4 layers as to make a very strong rigid mould.
Once i clean up the mould ill add the tunnel for the 2 pipes. Once done i can finally make the finished article. When i have time ill make the other panels the same way.
