Chasis - prep for paint - rust proof

First I removed the surface rust which I had let start in some places that had been welded.




Then I covered it again in vactan which stops the rust and provides a primer surface.






Made a patch for the passenger side brake cylinder hole.



Covered the 2 incorrectly made holes for the pedal bracket. I amazed my self by filling these with one weld and then grind. The result...



Patch in place and the holes either side filled with weld.


The old friend/ fiend, filler.



Vactan on top.

Chasis - prep for paint - pedal assembly

The play between the accelerator pedal and roller...

I decided to attach the original hinge to the floor with a 90 degree angle.






After some investigation (something that should happen before each stage of a project like this!) I realised that the pedal cluster bracket was the wrong way around. So I made 2 further holes in the correct place and had to fill in the old holes.


The master cylinder attaches below and the weight of your foot pushes onto it each time you hit the brakes. I was advised that it would be good to add some metal tubing between the double skinned outer wall and inner.







Then it was a simple matter of adding a stop to the floor. As can be seen below it would catch the brake and clutch pedals from returning too far.




Unfortunately the bit of scrap metal that I turned into a stop was it seems iron and no amoun t of welding would allow me to attach it to the floor.


I tried the pedals several times as its not good to get those things wrong! This was the order which I removed the pedal cluster.

Chasis - prep for paint - centeral brake line

Removed the tabs on the passenger side...


Made some new tabs to hold the brake line in place.






Then puzzled over the accelerator pedal. If I attached it to the floor at the level suggested in this picture, the stop on the bottom of the pedal would prevent it pushing against the accelerator arm.



One possible way of raising it up....

Chasis - prep for paint - handbrake

Unfortunately, on the new floor the handbrake cables came up short. The end of the pipe that houses the cable between the brake drum and chassis was short.



I got hold of some steel tubing. 12mm x 1mm (thickness) x 1m for less than £4.


It fitted snuggly over the tube that housed the brake cable and just needed to be welded to the short tube sticking out of the floor.







Then I assembled the rest of the handbrake.