DanM Posted February 23, 2023 Author Share Posted February 23, 2023 Todays challenge is to start working out how to make brackets for the 2 clutch switches (Neutral and interlock I think!?) that I have to install to pass my safety inspection. To be honest, I have no idea which one is which and the LAO1 looks like it is broken!! Not that that matters because the LHD pedal box does not have any brackets (or room it appears) to install them. So, once again I went to the local hardware store to find something suitable to repurpose. I found a 5" steel mending plate for less than $2 and went to work fashioning a bracket. First I drilled a 10mm hole for the switch. Then, I bent it in the vise and rough shaped with my angle grinder, before finishing it off with a hand file. All looks good after a test fit. Tomorrow I'll paint it and figure out how to mount the other switch.....not looking promising!! Link to comment Share on other sites More sharing options...
MV8 Posted February 23, 2023 Share Posted February 23, 2023 When pressed, the white switch allows the starter to engage. Link to comment Share on other sites More sharing options...
DanM Posted February 23, 2023 Author Share Posted February 23, 2023 6 hours ago, MV8 said: When pressed, the white switch allows the starter to engage OK, so I guess that doesn't have to be clutch operated!! Link to comment Share on other sites More sharing options...
MV8 Posted February 23, 2023 Share Posted February 23, 2023 Better to fit it and not need it. Being able to start the car in gear may be a no-go. If you'd like a method of fitment, I could draw on a pic of the footwell with the clutch pedal fully extended forward to the stop, as viewed from the right thigh. I'm sure you can do it with your bracket making skills. 1 Link to comment Share on other sites More sharing options...
Austin David Posted February 23, 2023 Share Posted February 23, 2023 $0.02 I've found it useful to start the car from the outside. And I've only run over my foot twice. 1 2 Link to comment Share on other sites More sharing options...
DanM Posted February 27, 2023 Author Share Posted February 27, 2023 Unfortunately, I was right about the clutch neutral switch...it was broken, so I had to order a new one from Mazda. The bracket works great and seems to locates the pin quite well. The only problem is access to the bolt so I may have to permanently fix it to the bracket from underneath and secure it with a bolt from the top. Next, I decided to fit the seats for fun. I made myself a small cardboard template and marked the hole positions on some painters tape, before drilling through with a stepped drill bit. Wow! Not much room on the left hand side. 1 Link to comment Share on other sites More sharing options...
panamericano Posted February 27, 2023 Share Posted February 27, 2023 Nice looking seats. The last photo seems to have Zoom Zoom Vroom Vroom sounds imbedded. 2 Link to comment Share on other sites More sharing options...
IamScotticus Posted February 27, 2023 Share Posted February 27, 2023 Very nice seats. who made them for Westfield? Link to comment Share on other sites More sharing options...
Austin David Posted February 27, 2023 Share Posted February 27, 2023 1 hour ago, panamericano said: Nice looking seats. The last photo seems to have Zoom Zoom Vroom Vroom sounds imbedded. Before I started I'd read in several builds about the point where the owner put in seats and sat in the unfinished chassis. I thought "no way." Then I did it last spring. I did not make the "vroom" noise, but my wife did. 1 Link to comment Share on other sites More sharing options...
DanM Posted February 27, 2023 Author Share Posted February 27, 2023 LMAO! I must admit there was a little bit of Vroom Vroom going on! lol Also, a lot of "squeeking" sounds as I shoe horned myself into the cockpit! Not sure if its the same for the Caterhams, but the Westfield chassis structure is the same for LHD and RHD. Unfortunately for us, the LH side (UK passenger side) is narrower than the RH. I'm 6 foot and about 200lb, and have now found an incentive to cut down on the booze and pies!! lol I had a look under the seats and they are made by Cobra. 1 Link to comment Share on other sites More sharing options...
Austin David Posted February 27, 2023 Share Posted February 27, 2023 I think mine is symmetric, both sides are the same size; both equally snug. My RHS has a channel for the steering column even, though it's all hidden by the dash. Link to comment Share on other sites More sharing options...
DanM Posted March 1, 2023 Author Share Posted March 1, 2023 So, I'm trying to fit in as many footwell related tasks that I can before riveting on the side panels. Today, I installed a small foot rest. It's actually an angle bracket from the hardware store, but in my humble opinion, fits quite nicely next to the clutch pedal and has enough structure to secure it to the panel (rivnuts and bolts) and not stress it too much. I also added a square aluminum backing plate for good measure. A bit OTT I know, but its done now. 😁 Hopefully there is enough room between the panel and the body!! 🤞 Finally, I took it all apart and gave it a spray of rustoleum all-in-one satin black. The other thing that I did today was print off the Ontario Safety Inspection Standard. I'm getting to the point where I need to really understand some of the nuances and make decisions about the final configuration I'll go with for inspection (E.g., OEM ECU vs Megasquirt). Plus, I have a list of Ontario specific safety items that I have to have... e.g., Bumpers!!! I'll start checking things off the list before I go too much further. Link to comment Share on other sites More sharing options...
MV8 Posted March 1, 2023 Share Posted March 1, 2023 If there is no bumper minimum width requirement, the nose can be called a bumper. Modern car bumpers are plastic covered styrofoam with a little sheet metal support. Link to comment Share on other sites More sharing options...
MPG Posted March 1, 2023 Share Posted March 1, 2023 Even though (because??) the footwell is so crowded in a LHD Westfield, the footrest is really useful. I made a 3D printed on that clamps onto one of the diagonal rails with a hose clamp. Link to comment Share on other sites More sharing options...
Austin David Posted March 1, 2023 Share Posted March 1, 2023 (a) I wanted a dead pedal on my first road trip, but by the end I'd figured out where to put my foot. And my shin-muscle developed enough that it wasn't a big deal. On ~ highways I just rest it flat under the clutch, and have muscle-taught the gymnastics to unfold it. (b) I will offer to print whatever in a lovely flat black, rubber or polycarbonate. Both will hold up to the heat and UV in an open car, but I like the rubber for things that you touch. Link to comment Share on other sites More sharing options...
DanM Posted March 1, 2023 Author Share Posted March 1, 2023 3 hours ago, MV8 said: If there is no bumper minimum width requirement, the nose can be called a bumper. The only thing I have read, is regarding the need to bring the car to a stop from a certain speed E.g., 5 or 10KPH. Link to comment Share on other sites More sharing options...
DanM Posted March 1, 2023 Author Share Posted March 1, 2023 3 hours ago, MPG said: I made a 3D printed on Looks great! smart idea! Link to comment Share on other sites More sharing options...
DanM Posted March 1, 2023 Author Share Posted March 1, 2023 2 hours ago, Austin David said: I will offer to print whatever in a lovely flat black, rubber or polycarbonate. Thank you! I've already drilled and positioned this one, but will keep the offer in mind! 1 Link to comment Share on other sites More sharing options...
MV8 Posted March 1, 2023 Share Posted March 1, 2023 (edited) 42 minutes ago, DanM said: The only thing I have read, is regarding the need to bring the car to a stop from a certain speed E.g., 5 or 10KPH. If running into a lake or snow bank, the nose "bumper" will do that once. Anything else just means a bit more damage. Edited March 1, 2023 by MV8 1 Link to comment Share on other sites More sharing options...
Austin David Posted March 1, 2023 Share Posted March 1, 2023 Just now, MV8 said: If running into a lake or snow bank, the nose "bumper" will do that once. Anything else just means a bit more damage. please post said picture of driving NEAR (not "into") a lake or snow bank. Link to comment Share on other sites More sharing options...
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