Assembling the STALKERV6 Bodywork

Page Three

The footwell firewalls are fabricated from the 13"x13" panels. The first step in laying out the left panel was to turn it upside down and draw a line even with the top of the frame crossmember. This will become the fold line for a flange at the bottom of the panel. A flange is necessary because it would be impossible to insert the panel behind the frame tubes.

Here are the details for the way I fabbed the left panel. The curved line is laid out by tracing around a gallon paint can.

Here is the left footwell firewall after it is cut out, the bottom flange formed, and a slight flange bent on the outboard edge so it will lie flush with the frame tube.

The panel could be made without the curved feature, but since the stock was large enough I added it because I liked the look.

Holes were drilled on 2" centers for fasteners.

The right footwell firewall is simpler because it doesn't require the bottom flange.

The notch for the inboard frame member needs to be a little oversize since it is necessary to insert the panel diagonally into position.

The finished right footwell firewall.

And......both footwell firewalls.

2/6/04
I wanted the inboard footwell panels (forward transmission tunnel panels) to have the capability of being removed with the transmission in the car. The panels come with a flange formed on one edge; I used that flange for mounting the panel to the bottom frame tube. Another flange needs to be formed on the forward end of the panel where it attaches near the pedals. A slight flange needs to be formed on the rear edge where the panel joins with the rear trans tunnel panel.

This photo shows the left panel, front edge on left.

The left panel installed. A slight angle was trimmed at the top rear corner to clear the instrument panel, and I tapered the top rear edge to follow the tunnel tubing. I will probably use that "tab" to attach a box surrounding the remote shift mechanism. The top of the panel can be pulled inboard enough to attach to the top tunnel tube.

Update; 2/25/04

When I tried to reinstall the left forward footwell panel after installation of the pedals........it wouldn't fit! The brake pedal assembly prevented the panel from being positioned to get it past one of the frame members.

It was necessary to trim the forward upper edge so the panel could be inserted past the crossmember above the pedals. With this trim made, the panel can be easily slid into place (compare this photo with the ones above).

A flange was fabricated and riveted to the "cutoff" from the panel. This was then attached to the frame; the rest of the panel is attached to the flange with a couple of screws. Since this panel is now easily removed, I see no need for an additional inspection panel at the clutch slave cylinder.

The mods necessary to fit the right panel are almost beyond description! A 1.5" flange is necessary on the forward end due to the offset of the frame tubes at the firewall.Once that flange is formed, it is a matter of fit and trim, fit and trim, etc. The corner between flanges has to be opened up due to differences in size of frame tubes. On both panels it is necessary to relieve the bottom rear corner to accommodate that the bottom tunnel tube is smaller than the frame crossmember. This panel will need to be pulled inboard as well to meet the top tunnel tube.

Footwells finished! There are numerous small gaps between panels and frame members especially around weld beads.....but we are building an open, unheated car! I may use some silver construction caulk if the gaps end up aggravating me later.

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