First Weekend of Box building

Well I just got back from A&E (more on that later) so am updating on the weekends work.  Again I was over in Milton Keynes with Craig 'cdfocus' Dillow this weekend making a start on the box build.

First up we had to cut and bolt the floor in.  Yesterday it was chucking it down with rain but we managed to get a lot done - including a visit to B&Q to get wood and a circular saw - Thanks to the 20% sale we got it all for a good price!

The starting point

Cut to size

And arches cut out

And dropped in

The back cut out and fitted

And both parts fitted in

Front section cut to allow the main wiring loom through - the wiring for the power and signal will be run under the car

This is as far as we got on Saturday so started today with the task of bolting the panels to the boot floor but before we did that we needed to work away of bracing the front overhang.  we started by drilling holes in the some 25mm mdf and bolting them down

This will then allow us to brace the overhang to the floor - pics coming up later - back to bolting the floor down.  On the tops of the ridges we laid down alot of PU glue

About this time I was crawling under the car to find a safe location to drill boltholes - on getting out from under the car this happened

A nice 1 inch gash right over my eye - but I bandaged it up and carried on working - hence why I only just got back from A&E

Bolted and tied down nice n tight

Once the floor was bolted in I could brace the front with some nice big fence post!

Once the floor was nice and solid we started on the sides - we were able to screw wood behind all the panels that we could get access to to allow us to screw through the wood panel, through the bodywork and into the wood mounted behind - sandwiching the  bodypanel

We were able to bolt the side panel to the door opening in 4 places - we will then also bolt the 2nd panels using the bolts

SPL FUEL!

The otherside went in a treat

We then started in the top panels.  As you can see from this picture we are coming right upto the front of B Pillar but had to cut around the seat belt

 
And the whole thing done - this is just the first 18mm layer - there will be more along with lots of fibreglass on the outside (where the doors are) as well as over the arches plus lots of expanding foam