View Single Post
Old 04-01-2010, 05:34 PM   #1 (permalink)
EcoModding Lurker
Join Date: Jul 2009
Location: London UK
Posts: 86

VW GOLF - '96 Volkwagen Golf MK3 GL
90 day: 50.21 mpg (US)

Commute scoot - '95 Suzuki AE50 Style
Last 3: 70.4 mpg (US)

The German - '99 Mercedes W202 C200 Classic
90 day: 27.65 mpg (US)
Thanks: 0
Thanked 9 Times in 7 Posts
Undertray / belly pan build - VW Golf MK3 1.9 Turbo Diesel

Today I set about starting my undertray build, I wanted to build and strengthen the tray before mounting it to the car for ease of removal.

I bought 4 large sheets of 2mm correx board (see pics below) with the intention of using a couple of layers to get the correct strength. Unfortunately the rigidity was awful so I had to strengthen the tray with some pieces of roofing plastic. You can see this in the picture as the ligher plastic.

The car has a front tray fitted from the factory (which I did a little correx repair work on this morning) so today I made the mid and rear sections. Because a MK3 Golf has a full width rear axle I had to build a separate rear section. You can see in the pictures how the tray is notched to allow movement of the suspension. You will also see that I have split the mid tray in half to allow the hot exhaust pipework to run down the centre un-covered.

The rear tray is a little longer than it needs to be as I will trim it once I have the correct angle for the "diffuser" part at the back. I think this will have to be spaced 20mm - 40mm below the bumper for optimum effect. It will also cover the exhaust back box as it will be cooler at the rear of the system.

I hope to have it fitted soon and put up some more pics, just a matter of fabricating some brackets to attach it to some convenient places under the car.

Attached Thumbnails
Click image for larger version

Name:	01-04-10_1444.jpg
Views:	322
Size:	83.4 KB
ID:	5884   Click image for larger version

Name:	01-04-10_1445.jpg
Views:	391
Size:	83.6 KB
ID:	5885   Click image for larger version

Name:	01-04-10_1542.jpg
Views:	329
Size:	98.7 KB
ID:	5886   Click image for larger version

Name:	01-04-10_1601.jpg
Views:	329
Size:	100.5 KB
ID:	5887   Click image for larger version

Name:	01-04-10_1837.jpg
Views:	373
Size:	103.2 KB
ID:	5888  


Will you recoup money spent on mods in fuel saved? see my spreadsheets here
  Reply With Quote