Instead of welding the brackets on Mika suggested using self- drilling screws and sent me along to the local (tiny) hardware store where I purchased the biggest they had - 6mm. Then we offered the guard up again, bolted the brackets to the guard and Mika drilled the two lower screws in:
Then we took the guard off and Mika drilled the horizontal ones in. On the lhs we had to take the intercooler pipe off but on the rhs Mika struggled to get it in past the compressor and it ended up a bit drunk.
The r/h bracket looked a bit too close to the intercooler pipe
So Mika took it off for some modifications...
While Mika was off doing that I took a pic with the camera lying on the ground:
Better:
The other problem we had was with the cage nut in the front crossmember, I measured it and ordered what I thought was the appropriate nut but it was too small. I suspect one like 6941 C0 (which is for the plastic undertray) would do but, rather than sod about ordering stuff again, I hunted around the workshop and found an M8 flanged nut, which Mika ground down to fit through the hole and tacked in place with the MIG.
Mika also cut down the two M10 screws that hold the guard to the brackets as they're ridiculously long and the l/h one also gets a bit too close to the intercooler again. 30mm would be plenty.
Was it interesting? Yes.
Did it end up being cheaper than a flimsy plastic one? Probably not.
Will it keep the water out? Umm...
