The new clutch system is now installed. The master cylinder has more than enough capacity to dis-engage the clutch without pushing it all the way down. The pedal position can be adjusted with the thread on the master cylinder so we've moved the clutch inline with the brake pedal. Due to the different leverage on the clutch it is now very easy to use. Only time will tell if all the problems are solve once we can go further than the end of the drive!
http://www.msportster.co.uk/data/p_construction527.jpg
Constructing the scuttle panel re-enforcement plate
http://www.msportster.co.uk/data/p_construction528.jpg
Heating along the cut to bend the 3mm steel.
http://www.msportster.co.uk/data/p_construction529.jpg
Re-enforcing the pedal box
http://www.msportster.co.uk/data/p_construction530.jpg
The metal is welded on in various places to strengthen the pedal box.
http://www.msportster.co.uk/data/p_construction531.jpg
Welding complete on the pedal box
http://www.msportster.co.uk/data/p_construction532.jpg
Scuttle re-enforcement plate painted and bolted in place, it bolts on to the bar than runs from one side of the car to the other. There is no flex at all when the clutch is operated now.
http://www.msportster.co.uk/data/p_construction533.jpg
Pedal box and new clutch assembly reinstalled in the car.
http://www.msportster.co.uk/data/p_construction536.jpg
http://www.msportster.co.uk/data/p_construction537.jpg

Exhaust Hanger Mark 2

Mark 2 exhaust hangers, these use the rubber mounts from a BMW 840Ci Sport. There is a 3mm steel plate that connects the exhaust boxes to the hangers.
http://www.msportster.co.uk/data/p_construction539.jpg
A new bolt is welded in on the right side of the hanger, the other is the one form the fuel tank strap.
http://www.msportster.co.uk/data/p_construction540.jpg
Driver side bracket, this one has some stress on it but the rubber mount is off a 12 year old car so the rubber has gone soft. A new pair will need to be ordered to finalise this.
http://www.msportster.co.uk/data/p_construction541.jpg
The plates need a coat of paint and this can be marked as done.
http://www.msportster.co.uk/data/p_construction542.jpg