After I finished the weekend, it didn't seem like I made much progress, but I'll take it.

I was able to get the floor pan riveted in (partial), modified the throttle side of the footbox for a little more go pedal room, and I built the dead pedal insert on the other side of the box, which was a big job. It still needs to be riveted in.

Throttle Pedal Side:

There are a couple of ways to get more room on the throttle side, either build an insert/box so you have more space, or do what I did...push out the bottom part of the panel a bit and add some support to hold it in place.

I ended up just trimming the bottom of the panel slightly, and I pushed the panel bottom out (towards the engine) about an inch. This gets me more than enough room for my size 11 feet (with tennis shoes or driving shoes on) and it was a very low effort fix.

Pic:



Dead Pedal Mod:

On long drives, you've got to have a place for your left foot, other than resting it on the clutch or shoving it under the pedal. Lots of guys have done the dead pedal mod, and I just copied one I saw on the forum. It's 2.5" on top and top front, 1.25" on bottom front, and flush on bottom rear.

I basically just cut a whole in the side panel after marking the cross bar, then I measured my additions and the bends from there. The initial bends weren't bad, but then putting the "ears" on those as the secondary bends were a pain. The first pic I saw I wondered why they looked kind of hokey (like they were bent with pliers...) I know now why they look like that...they WERE bent with pliers. That's about as good as you can get.

The .040 aluminum is thicker than the kit stuff, and it's an effort to bend it at all. I actually ended up a little aggressive, and the top of mine cracked a little. I added some angle aluminum I had around as a support.

All that's left is to silicon and rivet it all together.

Pics:





Steering Shaft:

I learned one of the downsides to buying someone else's kit is you can never find the parts you're supposed to have. I was missing my bellville washers (little spring washers), so I had to make my own. A couple of 1/4" washers, the grinder, a vice, and a screw driver, and they were made. These are what takes the slack out of the steering shaft.

I moved the bearing on the footbox to the inside to keep it clear of the brake booster, which was easy. The rest went in without a hitch as well, so the steering shaft is in, and working and tight...

Pic:

This pic shows some measurements a guy needed on the position of the shaft bearing assembly, and the angle at which it sits.





I hope to get my brake booster replacement soon so I can get that moving again. I also managed to sell about $300 worth of parts, so that'll help pay for some more new parts.