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Firewall and pedal box in a EL Falcon 

 

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 Post subject: Firewall and pedal box in a EL Falcon
Posted: Mon Aug 25, 2008 12:23 pm 
Tyre Shredder
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Well after discovering the cracked firewall thought I might as well go the whole hog and do the pedal box as well. Started pulling the dash apart yesterday and noticed that there were a few bolts missing here and there. I started to wonder if maybe some one had already beat me to the pedal box. This morning I lifted the entire dash out of the car and removed the pedal box and no surprises here somewhere along the line this car had been fitted with a brand new pedal box and I assume from the welding it has been already reinforced by the look of it. I have to say that the only problem which was a b**ch removing the dash was the fuse box and relay section, what a prick of any idea...Here are some pics of the pedal box, do you guys thing this is sufficient reinforcement enough..

 

 

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Posted: Mon Aug 25, 2008 2:14 pm 
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looks allright

but the welding is s**t!

maybe grind it off and re weld

 

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Posted: Tue Aug 26, 2008 9:45 pm 
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Should use a Mig welder, not a stick welder. And put a plate behind the pin on the inside to help spread the weight out. Fit new bushes, and lube them with Zinc oxide grease ( white grease ). Its for use on plastics, like door catches & the like.

 

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Posted: Wed Aug 27, 2008 9:42 am 
Tyre Shredder
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cjh wrote:
Should use a Mig welder, not a stick welder. And put a plate behind the pin on the inside to help spread the weight out. Fit new bushes, and lube them with Zinc oxide grease ( white grease ). Its for use on plastics, like door catches & the like.


Coiuld you edit the pic to where you say should put a plate behind the pin, noy sure where you mean..
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Posted: Thu Aug 28, 2008 8:50 pm 
Getting Side Ways
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nightstalker wrote:
cjh wrote:
Should use a Mig welder, not a stick welder. And put a plate behind the pin on the inside to help spread the weight out. Fit new bushes, and lube them with Zinc oxide grease ( white grease ). Its for use on plastics, like door catches & the like.


Coiuld you edit the pic to where you say should put a plate behind the pin, noy sure where you mean..


Sorry dude, I'm not real good at doing photo shop type stuff. But, you'll need some 3mm flat bar, about 40mm wide and about 125mm long.
You'll need to bend it a little here and there to get it to follow the profile of where it goes.
Where the strap sits on top of the the back of the clutch pin, will need a hole, about 1/2" in diameter. You will need to "Puddle weld" through this hole onto the pin to help with spreading the stress.
It doesn't need to be fully welded along the edges, just stitch welded.
This is how i have repaired many cracked pedal boxes, and none have failed.

 

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Posted: Thu Aug 28, 2008 11:54 pm 
Getting Side Ways
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Im in the process of fixing my busted pedal box. heres a few pics to help you out.

didnt end up fixing the broken one, i bought a new one and had it strengthend.

Image

Image

Image

 

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Posted: Fri Aug 29, 2008 12:03 am 
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how much was a new one :|

 

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Posted: Fri Aug 29, 2008 9:27 am 
Tyre Shredder
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Cant get then new any more, I queried my local Ford dealer and he said he cant get them anymore....
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Posted: Fri Aug 29, 2008 8:20 pm 
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nightstalker wrote:
Cant get then new any more, I queried my local Ford dealer and he said he cant get them anymore....


tell him hes on f**k drugs as i bought mine new 3-4 weeks ago

 

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Posted: Sat Aug 30, 2008 9:28 am 
Tyre Shredder
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I was told that about 2 weeks ago by Clancy Ford here in Bathurst, can I ask which Ford Dealer you purchased yours from and how much you paid for the pedal box..
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Posted: Sat Aug 30, 2008 7:48 pm 
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Buy the clutch pin from Ford and grab an Auto one and install it in that with plenty of reinforcement.

 

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