Cheers Scott! If it wasn't for the internet, I probably wouldn't have taken on anything like the projects that i'm doing. It's amazing what you can learn from all the helpful people online!
I'm finally back home, and jumped stright into the workshop and had a quick tidy up (it is still a mess but a far tidier one!)
Firstly I needed to modify my bike roof rack to fork mount as my suspension is too long for the racks arms to reach the downtube! I'm fed up with having to get the Saab mucky inside after muddy rides
Far stiffer now, I will remount the arms now so the bike is held on even more securely and so it can be locked on. Still got the other rack to do as well.
I also got a chance to play with the Commer today! I decided to scrap my first attempt at making an outer step, it was super messy as it was made of loads of bits of sheet welded togther, the angles weren't right and I just wasn't happy with it at all. I started again by making a cardboard template which helped me get my head around the folds and make a good chunk of it in 1 piece. The logical sensible way you might say...
The 3 drivers outer steps (original, 1st attempt and start of new attempt)
Clamped roughly in place, it fits!
Then it was time to get the fluted part made
And see how it looks against the old one
The lower part isn't finished yet, the curves near the back aren't correct and I need to neaten up the edges as well as getting the bends in. The step still isn't great but its 100x better than my original and hopefully with a bit more fettling I can get a pretty reasonable end result that only needs a thin skim of filler to hide the hammer marks!