Wheel arch Extensions
Because the axles now used are a lot wider than the original items, the body needed to be widened sufficiently to cover the tyres. This is a legal requirement. The easiest way of achieving this is to fit wheel arch extensions. There are aftermarket wheel arch extensions available for the lightweight although they only designed for the series III not the IIa with cut-off front wings. They also only add approx 1 1/2" at best to each side.
I needed to gain approx 6" each side. I decided to make something up from Aluminium. I tested various shapes by folding a small piece of Aluminium and trying it for size. In the end I decided to go with a slightly narrower wheel arch in Aluminium and then finished off with some stiff rubber. This produced a better looking shape than just using an Aluminium folded section.
This shot looking down one side of the motor shows the additional width achieved. Seeing it without the extensions really brings that old Carlos Fandango add to mind...
Also another benefit of having the rubber extensions is that these can be made larger or smaller depending on the wheel and tyre sizes.
Once I had decided on the correct profile for the section I folded a few 8' long sections up from a 16swg Aluminium sheet. I then went and purchased myself one of the flashy looking, ridiculously cheap mitre saws. I then set about measuring all the angles up ready to cut.
Once the angles where all cut and some end caps made, I dropped all the bits marked up to a local fabricator to weld up for me (I don't have any Ali welding equipment). The finished arches then went off to be powder coated black to match the rest of the body panels.
The next thing to do was to fit the rubber this was supplied ready cut in strips from a local rubber supplier. So all that I had to do was cut it to the correct lengths and then fix it to the arches by way of some more ali strip to provide support and some Ali Rivets.
There is then one last piece of rubber on the rear edge that mounts to the side of the motor. This is like a flat with a beading edge. It gives a very neat appearance where the two parts join. The wheel arches are held in place with M6 stainless steel hex head Nyloc nuts bolts and washers