And so to turning a give sheet or aly and a concept into a fitted and functional flat undertray.
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To say this thing has haunted my mind is an understatement.
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I'm found myself sat day dreaming of the logistics of the whole project for the last few days.
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Something which has been picked up on in management meetings, when I've been quoted as having a face which says
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"Phil's not here right now.
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Please call back next week"
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We last this story with me having taken delivery of a massive parcel and wondering what the hell I'd got myself into
![Anxious 8-[](./images/smilies/eusa_shifty.gif)
Well let's have a look see
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4489_zpsdbc9ac84.jpg)
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2mm thick, which in theory means less flexing when the car's moving.
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4493_zpsf7796ec3.jpg)
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Thankfully the packaging was thin fibre board, which actually turned out to be a blessing, as it was the same size as the sheet and could be used to make the template
![Dancing \:D/](./images/smilies/eusa_dance.gif)
This was a test to see how the proposed lines might work
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4494_zpsde818b80.jpg)
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Time to draw the outline and a rough guide
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4496_zps795ba899.jpg)
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So this is the basic outline, although it was set to be heavily refined
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4501_zps77b654df.jpg)
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First cut of the template
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4502_zps725c5686.jpg)
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Cut to a few hours later, lots of tweaking and refining
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4506_zps4e6c3eda.jpg)
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Which was enough for the day.
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Woke up this morning to see the great supplier of vitamin D in the sky
![Very Happy :D](./images/smilies/icon_biggrin.gif)
So cracked on with the job in hand
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4508_zps78d93009.jpg)
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Measurements checked, double checked and triple checked, it was time to put the first holes in
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4509_zps176e7ef8.jpg)
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I wanted to reduce the flared edges by 25mm, so marked up a 25mm reduction on the board.
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Giving me a line to mark the holes to
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4510_zps47d52530.jpg)
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All holes done it's time for a test fit
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4515_zps28dad84a.jpg)
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4516_zpsda140d64.jpg)
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Deja vu
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4518_zps8afe8454.jpg)
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Well would you look at that
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4519_zps4d2f4f76.jpg)
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4520_zps4d856c15.jpg)
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I'm planning on using the stock undertray plastics to hold the inner edge
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(line running along the edge of the tyres) in place, avoiding resonance.
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OS piece was fine
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4521_zps76ce5ecc.jpg)
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The NS piece wasn't so hot and had a split along the edge which needs to take the load.
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Nothing a couple of holes, a plastic tie and some evil strong glue over the whole area won't fix though
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4522_zpseebb8bc6.jpg)
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Onto the main event I guess
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4523_zps222ae9dc.jpg)
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One of the observations made during the test fit was that the extra material I'd left for the speed flaps was too much in reality.
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I did leave 60mm across the whole edge, however in reality 35mm is much more suitable and reduces the risk of it rubbing on speed bumps etc.
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So the template was shifted to compensate
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4524_zpsb7fc868d.jpg)
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Everything in the right place I thought it easier to drill a couple of the holes needed out in advance, so the two pieces could be held together, making the marking out easier and more accurate
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4525_zps10982e99.jpg)
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Marked up and ready for cutting.
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The inner edge
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(which meets the inside of the bumper) isn't perfect, however it's not going to be seen, so as long as the out edges and holes are spot on it works for me
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4526_zpscf2dad6a.jpg)
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Cut to many minutes later, ringing ears, lots of mess and a sore back.
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.
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.
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.
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The metal is cut, ready for de-burring.
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That however will need to wait for another day, as now it's time for BBQ food and maybe a drop or two of wobbly legs juice
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4527_zps362db45c.jpg)
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As with any Mule based job there's always some sort of sacrifice of blood required.
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This time the grinder decided it would do the business
![d'oh! #-o](./images/smilies/eusa_doh.gif)
Oh well, the dirt and metal particles will help it heal
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![Image](http://i1072.photobucket.com/albums/w373/Magic__Beans/The%20Mule%20v2/IMG_4528_zps55b0884a.jpg)
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So all that's left now is bolting it to the bumper, mounting and attaching it to the underside of the car.
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Oh, the speed flaps need marking out and bending too.
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The main thing is my brain gets to take a break from calculating and pondering
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Toodle pip.
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Hope you're all making the most of this rare blessing from the skies
![Dancing \:D/](./images/smilies/eusa_dance.gif)