23/3/2020

Most of the morning was spent make minor adjustments to the corner upright pillar to ensure a good fit.  Due to a materials shortage I had to add a small piece at the rear to support the inner lining of the boot space.  This was screwed and glued and left to set until the end of the day when I was able to sand it to shape to match the inner pillar, just to the left, that the boot door is mounted on.

The base of the inner pillar, where it meets the boot perimeter rail was very rotten and this had extended into the perimeter rail for about an inch.  I was able to remove most of this and make an infill piece to support the new inner pillar.

After lunch I modified the aluminium template for the outer pillar so that it could be used to manufacture the inner pillar.   The inner pillar is quite a lot thinner in cross section than the outer but is reinforced by blocks that fit between the inner and outer pillars.   Once this was made I was able to cut the new pillar for the boot door opening.

Last thing in the day I was able to screw and glue the corner pillar to the existing section but it has yet to be fixed at the base to the perimeter rail.  As yet I am undecided on how to do this.  I am leaning towards coach-bolting through the perimeter rail as this pillar proved additional support for the boot door pillar.

Outer corner pillar fixed at the top but not yet at the bottom,

Outer corner pillar fixed at the top but not yet at the bottom,