Untitled Document
  • 28th January 2012 – Fitting the pedal box and throttle pedal

    We started today thinking it was about time we fitted the pedal box. As we had already cut the hole in the footwell ages ago, its a job we could now do as the body is back on. The bolts go through the floor and flat section of the chassis and it was just a case of lining it up, marking up and then drilling the holes through. As the end of these bolts are exposed under the car, Mark had bought some stainless steel M8 bolts for this job, so they won’t corrode when exposed to the weather. Due to its position it proved a bit awkward getting these in and getting them tight. Mark bumped his head on several occasions while he had his head stuck down the footwell trying to get the bolts in (Hopefully knocked some sense in). We had noticed before hand that the floor of the body wasn’t quite square so we had to use a small piece of fibreglass, that we saved from cutting the original hole, to pack the front edge, getting a good seal between the vertical edge and engine bay.
    Next up was to negotiate the position of the throttle pedal. The throttle pedal is posted through a hole in the top of the pedal box with the throttle pedal housing mounted on top inside the engine bay. We read through the Hawk manual and it didn’t really give any hard and fast rules for the position, although when we had spoken to Gerry at the NEC he told us to aim to mount it about an inch from the front of the pedal box. So this is what we aimed for. We initially drilled a small hole posted the pedal through to get a rough position. We wanted the accelerator pedal slightly further forward than the brake and clutch pedals but for all 3 pedals to be equally spaced apart. From there we marked up the holes, drilled and fitted. This was also a bit fiddly due to it being under the wing and had to use a 90degree drill bit for this job.

  • 3rd December 2011 – Engine bay – extra metal panels

    We decided after a little discussion to make some extra aluminium panels for the well sections connecting the inner wings inside the engine bay to the pedal box and footwells. Originally we had planned to leave these as a fibre glass finish. We had some extra aluminium sheet left over from the manufacture of the other heatshields so we thought this would really finish the engine bay off nicely. So as went about making simple templates from a couple old cornflakes box to get the shape and size of the 2 well sections. The offside proved a little trickier than the nearside as we had to negotiate the gap for the pedal box.

    Marks cleverly had the idea to give ourselves enough overlap of metal to be able to fold the aluminium right over on its self on the edges which would give us a great finish. So this is exactly what we did.

    We then used tin snips to cut the template out of the 1mm aluminium before using the metal folder to get the shape and the vice to fold the edges over getting a really neat finish. Then we finally fitting and riveting into place on the car.

    I have to confess this was more Mark’s handy metal work than mine (in fact my first attempt was rubbish and we threw this away as a tester piece) but when Marks stepped in, his metal work skills got them both fitting beautifully. With a little polish, we both agreed that this little addition really added that little extra quality to the overall appearance of the engine bay and well worth our efforts. I hope you agree from the pictures.

  • 24th September 2011 – Extra fibre glass on the pedal box

    Mark decided to add some extra fibre glass to the floor where I had made the cut out for the pedal box. He cut a piece of fibre glass matt to bridge from the inner wing to the cabin floor. This is mainly to add some extra strength to the floor but also to level out the lip connecting the inner wing unit to footwell. We will probably finish it off by painting it white to match the pedal box.

  • 10th September 2011 – Extending the pedal box hole

    Due to the modification Mark had made to the pedal box by wielding a new flange around the edge, we had to spent a couple of hours cutting and extending the hole. The modifications now allow the pedal box to fit completely flush with the outside of the footwells and make the final job inside the engine bay really tidy. We made a cardboard template to get the shape and as before used a hacksaw to cut the hole then finished by filing the edges to get them straight and smooth.

  • 20th August 2011 – Pedal box adapted with new flange

    After seeing Andy Gordons FIA Cobra at the Silverstone show, Mark decided he would like to make a modification to the pedal box by welding an extra flange around the edge. By cleverly stepping back and wielding the new flange the thickness of the fibre glass, it means it will sit perfectly flush to the outside surface and make a really tidy finish inside the engine bay. This would add extra support as well as allow us to get a really good seal against the body when its fitted. It does mean we have to slightly adjust the hole we originally cut for the pedal box as it was initially our intention to make the seal directly against the fibre glass body so we cut the hole 1cm smaller all round to allow for this.


  • 22nd July 2011 – Cutting the hole for the pedal box

    After cutting the side vetns, next was the pedal box hole. This was a little more fiddly due to its position at the end of the foot well. Again the position for the hole was marked into the glass fibre body, so using this as a guide, we got to work marking it up using masking tape.

    TIP… Next, and importantly, use a second line of masking tape to mark the hole approximately 1cm inside the original line. This will allow a small lip behind the peddle box that can be sealed cleanly when you fit the peddle box and master cylinder.

    Once all marked up we drilled the corners, then using a small saw, cut around the edges marked by the second line of masking tape.

    Other extras we might consider.

    Once again after inspecting some of the beautiful 289 Register members cars at the Silverstone show, we have decided what we might do is wield an extra metal flange around the pedal box unit for extra support. More on this later.