What's in the workshop this week, Pelikanblau edition

[MikkiJayne]

Been mostly fiddling and fettling this week. Now that most of the big jobs are out of the way it was time to do something which has been bugging me for a while.

Because of the LPG tank, the boot carpet doesn't fit any more. This is a, most uncomfortable when working in the boot, and b, a most excellent tool-trap when things fall under the tank! I should imagine its also quite vexing if you want to use the boot too!

Nicht gut.



Cut a piece of 10mm plywood to fit the space.



Cut it in to two pieces. This is where the new floor will 'hinge'. The leading edge of this is tapered to lead the new carpet on to the original floor.



Painted the visible surfaces on the top



Sprayed the underside with sound-deadening paint



Cut the new carpet using a spare as a template



Made a support brace at the front end of the spare wheel well. This will support the front end of the lifting piece of the new floor.



The front piece of the new board sits on top of the support and is held in place using the studs for the original floor



New board in place. It all fits nicely



New carpet stuck to the board with contact adhesive



Stuck some anti-rattle felt on the LPG tank support braces so it doesn't squeak



All stuck together



In place and held down with the tie-down loops, and with D2 fuel-line screws going through the board on to the original studs.



Made a little handle to lift the floor up. The original plastic handle won't fit because of the tank, but since there's no spare wheel and the tyres are run-flats, I can't see much need to go under here!



Finished



Its black rather than dark grey since I've never been able to find aftermarket carpet that matches the D2 boot, but it beats no floor at all!