Hi heres the round up for this weekend
Bought a new welding mask (I'm not sure if i like it yet)

First up i set about removing the front carpet

making sure not to loose any of the fixings

I wanted to get at the offending gearbox tunnel

The carpets done well for 34 years of service

Is there supposed to be a lump of chip board here??

At this point i though oh toss whats it hiding, luckily nothing its quite tidy underneath


engine out again!

to get to the underside of the tunnel so i could see what could be done about the lack of space

After much fecking about i decided to move on to something else (more on the tunnel later)
Here is the next offending area

time to fit the new Corsa B brake assembly - this one below \/

spot weld time

after a quick sand over they all became apparent and i drilled them out with little drama

a bit crispy underneath, that's not a problem!

then it was out with the old brake assembly

to gain better access for some more drilling

I was careful with the important ones in the corner not to drill through.

Time to get brave and cut a big hole - it will become clear why I've cut so much out

more spot welds successfully removed


part of the heater blower plastic needed removing

to gain access to cut out some more metal

So as seen when others have added the corsa B brake assembly (like Darcy's below) you need to raise the whole assembly to get the pedal height right without cutting the pedal arm etc.


to avoid having a raised platform area i want to raise the height of the whole area so it looks more original and strengthen it while I'm there.
I will be following this line

In order to do that it was necessary to chop some more

getting there now

all the spots behaving again

a quick sketch

ready to be transfer ed to 2mm sheet

I then had to move to my phone camera as the batteries on the other one went flat so pic quality isn't great from here on in.
I set the corsa B assembly up on a threaded rod so i could adjust the height to suite

then set about the lower part of the bulk head to remove the holes left by the old brake assembly and generally strengthen the area with some more 2mm

this lot needed cleaning off first

as so


area below the rule needs filling first

I started with this

Some bending


And welded that in

Stage two the top part, roughly marked out

more bending


i used a piece of box here instead of angle to get the correct radius

as so

Tweaked these edges up with the mole grips

so it fits here

as so


Drilled the spot weld holes


Cleaned the edges off and tacked it in

And some more welding

in nice and level

finished off the welding


It could have come out worse


Hopefully it mirrors the other side to a certain extent


Once its all sealed up it will blend in well

Thanks
James