So my exhaust has recently been doing my own head in. It's not too bad just tootling along but any sort of hill or push of the accelerator that's when car alarms start going off and houses are falling down. Not ideal So I've decided to go for a full stainless system to the back!
But due to being low the back box I have got don't fit between the bumper and ground. So that gives me the perfect opportunity to go ahead with one of my other mad, pointless and OTT plans... cutting out the wheel well and making it a flat floor..
So that is exactly what I done yesterday.. i died a little inside but deep down I knew that the finished product would pay off well and it'll look awesome.
i set out cutting around the wheel well, chiselled off the soundproofing and cleaned up the metal around where I'll be welding
this morning i picket up a 2x1 sheet of 1mm steel and 2x1 sheet of 0.9mm Aluminium.
i traced around the cut out wheel well and added on an inch or so all around so that I had plenty to play with and trim down if needed
i then placed it in the boot, measures where I needed to fold to step up the boot, this will also give the new floor extra strength.
placed it back in the boot and everything still lined up great
i then set to making the second piece that comes up (last picture)
same process, made a cardboard template and cut that out the sheet metal too, slotted into position and made markings on where to fold for weldind onto the top piece, this will also give it strength
it is coming along really well, it was daunting at first but once you set your mind to it and you don't rush there's not much that can go wrong
tomorrow will consist of trimming the top piece to the cleaned area of metal on the car, then weld it all up and apply body sealer, and paint underneath to protect from rust
apart from making more room for the big back box I got the other reason for cutting the boot out is so that I can make a big diffuser hence why I bought a sheet of aluminuim
but the diffuser may wait for a bit until my exhaust is nearly done, so that I know where to mount everything and just make everything as easy as possibly for myself