No more avoiding it - time to chop some holes in the body! It is much easier to cut from the wheelarch compartment side:
The next step was to drill the five fixing holes for the pedal box. I had decided to fit a spreader plate to the compartment side of the bulkhead and this was made up as an exact match to the pedal box:
Having marked the first hole position I could then use the plate as a template for drilling the other holes:
You can see from this photo that I've temporarily fitted the steering column support frame - using washers to pack out where the windscreen frame would go. The steering column support frame also supports the front end of the pedal box as you can see below:
The steering column support frame needs to be drilled for Rivnuts so the pedal box support can be bolted to it. I'm not going to do this until the windscreen has been fitted and the support frame is in exactly the right place. The pedal box was then bolted up and checked for clearances:
I then removed the pedal box in order to put it all back together. First thing to do was to drill and slot the end of the accellerator pedal to take the nipple on the end of the accelerator cable:
Next job was to fit the brake light switch - which means drilling holes in your nice pedal box!
Finally I re-fitted the master cylinders and checked the operation of the brake light switch.
And there you go.... before you know it.... a whole day gone by!! Definitely a case of measure 10 times cut once!
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