Hi Steve and welcome,
I got your direct email, too.
I've not heard any more from John Swauger at TRF, if they plan to make skid plates or not, although I've talked with him a couple times in the past month about some backorders that are making me crazy. TRF does have an original skid plate to use as a guide. Maybe they'd produce something better than the one you bought from Moss. Or, it might be the same thing. It doesn't seem like a terribly complicated thing to make.
I've also considered just fabricating one out of steel or aluminum. Wish I had an original to look at, but meanwhile I've already mocked one up out of foam core.
Can you tell me some more about the one that didn't fit your car and why? From illustrations I've seen, the triangulations on the inside look pretty important, to add rigidity. Did you remove the original radiator guard from your car? Or, did they interfere with the bottom of the radiator?
As to fastenings, the one I've mocked up is intended to use the four existing holes in the side rails of a TR frame, and the two in the bottom of the cross member at the front of the engine. Those last two would need to be drilled the rest of the way, through the top of the cross member. I worry a little about any weakening of that cross member. I suppose the best way to install using those holes would be to weld a 1/2" OD pipe (3/8" ID) inside each, much the way Triumph original did with other through-bolts on the frame. Overall, in order to position the skid plate below the existing holes, it seems to have come out a little larger than the originals I've seen photos of, but again I can't be sure.
I know some folks used to simply weld the skid plate in place. That might be best for frame rigidity, but personally I'd prefer something that could be unbolted for access to various stuff at the front of the engine.
Paul, the original skid plates did little to protect the oil sump. On the other hand, the original pressed metal sump cover is flush with the bottom of the frame. If it's hanging below at all, engine mounts need replacing or shimming up, so you did the right thing.
The original skid plate apparently wouldn't work with the cast alloy sumps offered as an accessory by Triumph, nor with the deeper ones available today. The cast sumps are deeper than the pressed sheet metal version, mainly because of the thicker material and the oil pump pickup inside. Today there are special, shallower cast alloy sumps available, that also end up flush with the bottom of the frame, but require changes to the oil pump pickup, too.
What I don't understand is how there would be a problem with the skid plate, used in conjunction with any of the various sumps. The plates I've seen photographs or drawings of all appear to end right at the rear edge of the frame cross member, so shouldn't interfere with any sump put on the car.
By the way, I've looked at TR250/5/6 skid plates too, and the mockup I've done borrows the idea of optionally using it to attach the front sway bar. I'd also drill a number of holes in the center of mine, to direct more air into the oil cooler and radiator on my car.
Any pictures of TR skid plates anyone can offer would be great!
Cheers!
Alan Myers