[sallen]

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.