Parts drawings and custom modification thread - Let's share.
I though there might be interest in creating a thread for sharing (not-for-profit) parts drawings and custom modifications, beyond what already exists in the main topics (at the top of this site). I'm planning on making some stuff for myself and I don't mind sharing my work. I don't plan to sell it because I don't have the time. I'm also curious what other improvements some have made to their Defenders. Seems like a lot of you guys are sitting on good ideas out there.
Here's what I am working on. I wanted to try out Solidworks nifty sheet metal features so I built a driver and passenger toe box assembly in 3D. The software allows me to build it the way it would be installed but the pattern can be flattened out at the push of a button and I can send the flat part to the machinist. The rubber toe box I have sucks so I thought I'd have one built out of sheet metal. I want one that doesn't sag, can take abuse and that is easy to clean. The one I plan to make (pictured) consists of two parts. The side part slides in first. There would be holes on the side for the door grommet (speaker wires, etc) and once that part is in, the main parts goes in and locks the other one in place. I have done a first round cardboard mock ups and I am now adjusting the 3D based on some changes I need to make after the first fitting. I am doing all my measurements based on a layer of Dynamat underneath.
The other part I plan to make is a trim piece that would cover the edge of the seat box. The seat belt attachment would have to be removed to install this. This is the part in the 2nd picture. This would have to be thin enough that it doesn't interfere with the door seal but sturdy enough that you can stand on it.
Constructive criticism is highly appreciated.