Rear Boot / storage area

Focus is on moving back to front with the build, rear panel has been successfully vinyl wrapped and permanently fixed into position (no going back on that decision now!)

I have a nice bare area aka "the boot" which needs completing and there is nothing of significance left to do on the rear end which is preventing me from focusing on getting the boot to a finished position.

GBS do the rear boot panel kit (luggage infill panel kit) which comprises:



Differential inspection panel (needs a hole cutting out)
x2 inner closing panels 
x2 rear closing panels

Looking at the panels it is relatively self evident where they fit, the main area of work is in cutting an access hole through the differential inspection panel to create access to the rear diff, brake lines etc (this is required for IVA in the UK as the testers will want to look in this area)

Simple jigsaw job of cutting through the panel, drilling four holes and inserting rivnuts through the holes. You will need a further piece of metal to cover over the hole you have just cut ( I need to get this still!)

Another piece of work which needs doing is to drill a hole in the rear closing panels near the top, to provide access to the retaining nut/bolt for the rear shock absorber. I appreciate it is unlikely there will be a need to remove the shock however I want to build some "future proofing" into the build on the off chance access is required. Again a simple process of using a step drill to drill through the panel to give a big enough hole to accept a socket.

Once all the above is done its a case of put with the polyurethane sealant and fix the panels into position, start with the differential access panel first, followed by the rear closing panels. 

With the rear closing panel remember to route the fuel sender cable through otherwise the sender will not work!

the inner closing panels looking at the GBS instruction suggests the top section of the panel goes under the steel chassis section - this in my opinion is not possible due to the powder coating changing the profile of the gap the panel goes under. Speaking to GBS about this they confirmed the panels can be just glued access the top of the steel and not to worry to much about the top going under the steel chassis, So over the top the went!

Panel in - ready for carpet laying