Adding a Tool Compartment

Taking out the plywood boot floor for the first time to replace a leaking fuel filler hose revealed a certain amount of 'wasted' space between the floor and the top of the petrol tank, and it occurred to me that it might be put to good use. The boot is already small enough without a jack, tools, jumper cables, spare parts etc., and a recessed compartment let into the floor might provide enough room to store all those rarely needed odds and ends.

I understand some like to stow the jack under the bonnet, but I have absolutely no doubt whatsoever that the first time I'll need to change a flat tyre will be in the pouring rain, or on the motorway, or both... and getting the bonnet off at the side of any road and finding somewhere safe to put it would just be another aggravation I didn't need. (The K&Ns really don't help...)

As is so often the case, it wasn't as straightforward as it first appeared. The bottom of the compartment needs to clear the fuel sender terminals, but at that depth there isn't sufficient space to store the jack. Stepping the bottom down clear of the sender gives another few millimetres (limited by the cable passing over the edge of the tank) but this still isn't deep enough. Dropping it down forward of the tank edge provides just enough room for the jack foot with the jack lying on its side.

It's very tight - the dropped section cannot extend too far forward or it would hit the edge of aluminium floor as the plywood is pivoted upwards for removal. Nor could it extend the full width of the compartment because of the position of the tank outlet pipe, so it was made just wide enough to house the jack foot.

A section of floor around the filler hose was fitted separately. It would be impossible to remove a one piece floor with the compartment attached, and the second section simplifies access to the hose itself should it ever need to be replaced again.

A certain amount of lightness has been subtracted... but the original ply floor weighed 1.3kg, and the new flimsy Wickes 5.5mm ply floor and tray 2.1kg, so only 800g.

The plywood and aluminium angle construction took a ridiculous amount of time and effort, but I would imagine a simple one piece glass fibre moulding could be made if anyone was so inclined.

(Note to self: More pictures and diagrams to follow...)