Right Hand Conversion - Part 5 (Wilwood Pedal Box)

Due to the cost of a mustang pedal box being so high especially the cost of the clutch pedal alone would have cost me more to import than the complete Wilwood pedal assembly I decided t go this route.  First I fabricated a box for the firewall with the same 50 mm (2") height as the factory box.  

I then started the fabrication of the pedal support to hold the wilwood pedals.

Crush tubs made from the sleeves from a couple of dynabolts.

Completed pedal support assembly.

Holes drilled for master cylinders and ready for welding to firewall.

Firewall prepped ready for welding the pedal box.

Right Hand Conversion - Part 4 (Firewall)

Removal of the right side of the firewall, I did the replacement in 2 parts as to not remove to much strength from the firewall at once.

Firewall completed ready for grinding and some panel beating.

Right Hand Conversion - Part 3 (Dash Panel)

Marking out the dash ready for cutting into 4 pieces

Cuts made ready for welding back in on the opposite side.

Welds complete and cleaned up.

Test fitting back in the car.

Right Hand Conversion - Part 2 (Wiper Transmission)

This started with modifying the lower wiper motor bracket mount due to the different cowl contours on the right side.  This was achieved by cutting and re-welding the bracket so that one side is shorter.

All the brackets have been moved to the opposite side including the modified motor mount bracket.

Marking out of the wiper transmission motor spindle hole to reverse to allow correct park position.

Folding down of the transmission stops to allow swapping of sides.

Right Hand Conversion - Part 1 (Lower Cowl)

Well I started the right hand conversion which involved cutting out sections of the lower cowl and transferring to the opposite side.

Oops shouldn't haven't assumed that every thing is a mirror image, forgot the the wiper motor mount is offset so need to move the mount 65 mm to allow for it.

The lower cowl is now complete the brackets on the underside have also been moved and modified which will been seen in Part 2.

Boxes ... and a finished lower cowl

The other day I received a delivery from the states of all the parts that I will need to complete the cowl area including the lower cowl, wiper transmission, wiper motor mounting , motor and export brace.

 

 

Installed the lower cowl using the export black to help line it up due to the previous work done on the car (I use the term "work" pretty loosely) and the repairing of the firewall flange I was not 100% on weather I had left the right holes turns out I had and after opening them up a little and trimming the top edges I was looking good for welding.

 



 

Prepping the lower cowl for install removed the e-coat from the area to be welded and sprayed with 2 coats of copper weld-thru primer the punched and drilled the 8mm (5/16") holes rady for plug welding.

 

Installed lower cowl lined up with reference points and clamped in prep for welding.

 

 

And 1 hour 45 minutes later and 75 plug welds, one completed lower cowl.

 

 

Plug welds all cleaned up ready for priming with weld thru primer.



 

 

 Weld thru primer done ready for the rebuild of the upper cowl.

 

 

Next will be installing wiper trans to help line up the upper cowl and rebuild the pieces removed in the cowl removal process thanks to the mess of a job done previously.



Sub frame connectors

I decided to have a go at making a set of sub frame connectors using Car Daze's plans (see Car Daze Sub-Frame Connectors) and I must say I am very happy how they turned out.  Because I live in New Zealand the cost to purchase a set from the states and get them shipped here with the exchange rate was quite expensive I think they worked out to be about a third of the price and I still have enough steel to make another 2 sets.  Also making them myself allowed me to make some modifications to the rear mount to add more strength for when I add the through rocker exhausts.

Started by cutting the 2" steel to length and marking out the notches for the angles and cutting them.

I made a angle gauge out of a scrap piece of particle board to make sure all the angles are correct and welded the bends.

After welding the bends I ground the welds smooth and created a template for the torque box plates I made these different to car daze because I am going to cut a 3" hole through the torque box for the through rocker exhaust so this allows me to add some strength back I also cut the 45 degree angle at the rear end and welded in a plate to cover the opening.  I have also completed some of the installation phase by cutting the ends off the front frame rails to allow test fitting before fully welding the connectors.

Completed connectors with a coat of paint ready for installation.

Completed the installation of the sub frame connectors which was quite awkward due to not having any jack stands and doing it all from within the transmission tunnel at normal ground clearance.  Very impressed with the result and how much it has stiffened the body it is very noticeable when rocking the body from side to side.