Thread: CJT's D2 Rear End Fitout

I started the rear bar today with all lights purchased (LED lamps ADR approved) and the first light cutout being completed.

The lights still sit around 5 - 10mm proud of the bar so I am thinking of making up grills to go over them.

The main section of steel is 150x50x2mm RHS and is 1580mm long.

Lights are LED Autolamps and can be purchased from Autobarn, (Indicator = $50 each, Brake / Tail light = $50 each, Reverse lamp = $110 each, Gromets = $5 each, Wiring loom = $10 each)

Prices are approximate and I will put up a full list of materials, part numbers and prices when I am finished.

I also made up the rear door card out of 3mm alloy sheet.

I replaced all of the original trim clip points with 8mm rivnuts / nutserts and attached the card with stainless alen key bolts, I need to find some dome head allen key bolts to finish it off.

Next step is the fold down kitchen and bench.

I got to spend another couple of hours stuffing around this afternoon and I got the cutout for the second light completed.

So the passenger side lights are now done, I just have the 2 exhaust outlets to do and the 3 lights on the drivers side.

At least it took half the time as the first hole did.

Here is a quick model of the outer sections of the rear bar.

I will look at mounting points etc. at a later stage.

Originally Posted by CJT

I also made up the rear door card out of 3mm alloy sheet.

I replaced all of the original trim clip points with 8mm rivnuts / nutserts and attached the card with stainless alen key bolts, I need to find some dome head allen key bolts to finish it off.

Next step is the fold down kitchen and bench.

I dont suppose you modelled the cut out of the door card like you did the bar?? and thus have a CAD file handy to share?

Originally Posted by Hamish71

I dont suppose you modelled the cut out of the door card like you did the bar?? and thus have a CAD file handy to share?

Sorry, I dont have at this stage.

I only made a ply wood template, however I may do so in the future.

The aluminium door card/table is on my to do list, so will watch, and learn your lessons

Originally Posted by Hamish71

The aluminium door card/table is on my to do list, so will watch, and learn your lessons

I wouldnt watch mine to closely, a bit rough around the edges.

I do want to measure it up properly and have the card laser cut and pre-drilled for a nice clean finish.

I figure what I have now is good for development and it does not matter too much if a few holes end up in the wrong spots.