Throttle cut out

 Once we had fitted the seat it became apparent that the pedal s were to high and driving would be very uncomfortable .pedals out and back like the Hokey Cokey  .

After the final fit there would be no advantage to having the throttle cut out i have previously done . So i have fiberglass the foam back in ,this will make the carpet a bit easier to fit (hopefully )

Foam glassed back in 

Pedal box pipes

Started to fit the pedal box pipes as had a bit of time .Started with the clutch as that is the pipe that must go to the rear of the car .



Brake feed pipe and supply pipe fitted


 

Clutch pipe fitted to rear  

Pedal box Fitting

Fitting the Pedal box is a two person job at best .Took the pedals off to try and get it lined up right



Fastened with 1 bolt so I can get it level and check the holes still line up  

Read on other blogs that the cylinders need to be spaced off with washers so as I had some ally plate put that on the back to try and compensate !?
Still didn't work as I still had to cut 3mm off the clutch cylinder thread but worked a treat for the brake cylinders


Fitted finally

 Some confusion with which master cylinder goes were as there are two different sizes
0.75 and 0.625 I was convinced that the bigger one should go to the front but was labelled up the other way round  a call to Andy and I was wrong the smaller one goes on the front !!

Fitted with 2 mm of free play and the bias bar fitted the right way round
 



Throttle cut out

As mentioned on a previous post decided to cut out the double skin next to the accelerator like other cobra owners as things  are a bit tight down there .
Copied Dales measurements from his blog and went for 50mm up from the floor and went 220mm up 140 across at the top and 205 across at the bottom .
Didn't use a hole saw as I was scared that the pilot drill may go though the outer skin so went in "cold" with the dremel mini cutter .
It was easy to tell when I was though the fibreglass as the cutter goes easy .
This has left me with straight corners instead of rounded ones which I think I like but may regret this at a later date when it comes to carpets etc


View of the cut out from the clutch cut out

 

View from the drivers position
 

Need to get hold of some west system figre glass now to tidy the area up .

Update ++
Went to a local Fibreglass dealer (Ian Flockton ) who told me I could use their  resin instead of the west system as it is compatible with foam (blue in colour).VERY sceptical was I so he gave me enough to use as a test o the foam I had cut out and it is fine and less than 1/2 the cost result ,well happy 

Pedal box

Looking at blogs I realised that it was not just a simple job ( what is ?) of fitting the pedals .
Sitting on a make shift seat (2 bits of wood and a quilt )guessing the height as no seats yet , figured I would go with the recommended height suggested by Andy from GD .
Next was the pedal spacing as everybody else seems to bend them apart a bit ,can see why with all that power catching the wrong pedal would be interesting to say the least .
Comparing the pedal centres to my Insignia
That had 6 cms between the clutch and brake and 6cms between the brake and throttle .
On the pedal box I had 5 1/2 and 4 1/5 respectfully .
I set to to bend these in the vice with a large adjustable spanner moving the brake 15mm to give me 6 cms and the clutch 20 again to give me 6 cms .

Hopefully this will make sure that my size 11 shoes will only touch the intended pedal.
This is still a bit of a gamble as know it is rather snug in the foot well .should know better when I fit it .
While the pedals were apart I drilled the top of the throttle .
It requires a 6 mm hole 1mm from the top in 8mm bar so a bit tight .
I have cheated a bit and drilled a 5.2 mm hole and taped it 6mm
Also plan to follow other cobra guys and cut out the side wall to give me a bit more throttle space more on that later dremel out again .
 

pedals after adjustment (can just see the 6mm tapped hole in the throttle)