Footwell Update

I sealed around the clutch footwell extension using some black sealant and bolted it up.  Hopefully no water will get through.

I also covered the pedals using non-slip grip tape.

Throttle Pedal Wiring

Because the electronic throttle unit is on the opposite side of the bulkhead in the drivers footwell, I needed a way to get the cable and plug through without leaving a big hole.

I decided to design a piece that would allow this.  Basically I worked out what minimum size of hole I needed for the plug and then worked from there.  The cable itself, within the flexible conduit, could fit through a standard 20mm grommet.  This meant I could create a piece from aluminium to cover the hole up once the connector had passed through.  Again, I used Solidworks to design and a local company Ocean Kinetics to mill it for me.  I polished it on the polisher before passing the wire through it and fitting to the bulkhead with M5 button head set screws.  I had to dis-assemble the connector to get it through.

Footwell Extensions - Update

If you can recall I cut out a section for my right foot: here

After trying the accelerator pedal in it's motions, I decided to reinforce the footwell extension that I created which removed the inner skin.  I used some carbon fibre matting with resin to create a strong patch.

I cut the matting to shape, and then had to find bits of wood for props and also make a clamp frame to evenly spread the pressure.  This looks like a true "Crofter" style of set-up, but it did the job perfectly.

I applied just resin around the area first and let that set.  I then applied resin to the matting, both sides, before putting it in place with my clamp system.  The blue plastic was used to cover the clamps so that they didn't stick to the resin.

I think all in all a good job!

Please Note: This Modification IS NOT RECOMMENDED by the factory and I have carried this out at my own risk.

Footwell Extensions

I cut out for the footwell extension a while back, but never got around to fitting rivnuts to the cover, so I marked and drilled for 6x M6 rivnuts.  5 of these come through into the footwell, where 1 goes into the master cylinder compartment.  This was temporarily fitted, and will be finally fitted once the body shell has been put on.

Also, taking some pointers from Mark Turnbull's blog and Dale's blog, I decided to open out the footwell adjacent to the accelerator pedal.  I may need to slightly modify this once the accelerator is fully in place, however I copied what Dale had done here.  I will wait for the accelerator is in place and checked before applying glass fibre matting to the area. 

Please Note: This Modification IS NOT RECOMMENDED by the factory and I have carried this out at my own risk.