After I'd cut the rear wheel studs and got everything sat straight, I decided to have a go at the bonnet. It still doesn't line up properly. Well, it doesn't line up properly for me! The trailing edge sits half an inch or so lower than the body. I had thought it just needed some padding, which is why I bought the extra foam strip. Turns out it needs a bit more than that.
What I've done is drill holes on the corners, one about three inches in from the top and one about three inches down, both sides. Then using a nut and bolt I was able to dial in good positioning for the corners. I could do with a bit more working space but actually it worked quite well.
The bonnet sides now need to be curved to match the body sides. The middle part needs to come out, and the bottom needs to be pulled in. That will work well with the bonnet catches I have, I just need to make sure there are suitable fixing points all the way round. I'm not convinced foam is the best way to go, although it will stop the squeaking that currently happens when I roll it in and out of the garage! I think I'm back to 3D printed brackets, not as big and bulky as the ones I did before but probably more curved to allow the bonnet to drop into place. And they will reuse the holes I've made doing the bolt adjusters, so they should be very secure.
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