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Thread: Extending S2 passenger footwell

  1. 31st December 2013, 08:01 PM #1
    reg of the overflow
    reg of the overflow is offline Fossicker
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    Extending S2 passenger footwell

    My '61 SWB blew an engine some time back and while it was out awaiting a transplant I took the liberty to do a few things - re-wire; clean up stuff and general tidy up.

    Wifey has trouble sitting in the passenger side as she has long legs and cramps up. While the guards are off I am repairing rust in the footwells and am looking at extending the footwell about 6 inches or so. Seems easy enough as I have plenty of room but I was just wondering if anyone else has done this and could give me some tips. I'm not real crash hot at welding either but have plenty of rivets and galv steel sheet


    cheers - and happy new year
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  2. 31st December 2013, 08:38 PM #2
    Lotz-A-Landies's Avatar
    Lotz-A-Landies
    Lotz-A-Landies is offline Super Moderator Gold Subscriber
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    You may be better removing the top of the transom behind the seats.

    Bulkhead Removal Bar

    You won't find me on: faceplant; Scipe; Infragam; LumpedIn; ShapCnat or Twitting. I'm just not that interesting.
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  3. 1st January 2014, 07:47 AM #3
    chazza
    chazza is offline YarnMaster
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    Quote Originally Posted by reg of the overflow View Post
    While the guards are off I am repairing rust in the footwells and am looking at extending the footwell about 6 inches or so. ... I'm not real crash hot at welding either but have plenty of rivets and galv steel sheet
    Sounds feasible Spud; but make sure that the wheel can't hit the footwell when the springs are fully compressed and you will probably have to make a heat-shield, to stop the exhaust cooking your passenger.

    I don't think rivets will be enough structurally, but if you use about 12mm lap joints, you should be able to rivet and glue the panels in place using Sikaflex Adhesive.

    Alternatively; rivet the panels in place and get someone else to weld it for you,

    Cheers Charlie
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  4. 1st January 2014, 05:04 PM #4
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    garrywlh
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    sikaflex

    "I don't think rivets will be enough structurally, but if you use about 12mm lap joints, you should be able to rivet and glue the panels in place using Sikaflex Adhesive."

    This interests me Charlie. I have 2 brand new foot wells yet to be attached to my bulkhead. I was going to look into spot welds, but do you reckon the sikalflex/rivet combination would be sound? If so, I might have a try at that instead.

    Thanks,

    Garry
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  5. 1st January 2014, 07:17 PM #5
    chazza
    chazza is offline YarnMaster
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    Welding is my first choice, but as long as the panel isn't under great stress, or holding onto something important like the steering box, then glue should be fine.

    I always like to think of the worst-case-scenario when I do repairs, or modifications - what is the worst thing that can happen if this fails at 100km/h? If the answer is death, or injury I don't do it; if it is wet feet, I give it a go and monitor it.

    I had a look at my S3 after my first post and then remembered the LH steering box mounting-bracket, which also supports the bulkhead. Some of this bracket can be removed - I am going to do that for my 200tdi conversion - but you will need to work out how to support the bulkhead if that bracket has to be moved, or modified. Definitely a safety issue if the bracket is removed and not replaced,

    Cheers Charlie
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  6. 1st January 2014, 08:07 PM #6
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    harry
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    I had a similar problem when I got my shorty 2a, not enough room for me in the drivers seat. Driving it home the day I bought it, I popped the seat back out and put a carpet floor mat in for a back rest, this gave me more leg room . Since then I have had a thin seat back made in the same style and also reversed the squab so that my bum is a bit higher, giving me a bit more leg room.

    I don't think you will gain much room with moving the foot well forward, there really isn't much space between the tyre and the floor, unless you fit small tyres
    Safe Travels
    harry
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