Widening footwell part 2

Widening the footwell part 2

Once I had the hole cut out, I then reinforced it with resin and glass fibre, overlaping the edges and on the back of the outside panel using West System Exoxy Resin (this helps maintain the structure of the body, whereas normal resin may not bond as well) and glass fibre matting.

The resin is mixed 5:1 (resin to hardener). I made sure that everything was ready, as the resin starts to go off very quickly, so I had to work fast. The resin mixture was applied to the hole, the glass fibre matting was then put in place, then the resin was applied to the glass fibre matting with a brush (Tip: get throw away brushes for this). The resin was applied and worked in a stipple manner, rather than a painting action, then left to set. During this process I created gentle slopes at the top and the edge nearest the driver to avoid catch my foot.

Glass fibre and resin added to top and bottom of hole. The sides and back were next.

This is a messy process, made more difficult by the location. The hole will be rubbed down (take care here as glass fibre can get in to your fingers if you are not careful) and then lined on the flat area of the hole (not the edge) with carpet. This will reduce the space gained to 30 mm, giving the same space either side of the accelerator pedal.

Glassed extension

NOTE: This modification is not recommended by GD.