Pedals and toolbox lid

Swiss cheese.  That's what the driver's side firewall is.  By my count, at least thirteen holes.  So I put the Bronco pedal assembly up where I want it to be (tight fit, but will work well), and then I painted some self-etching primer around it to help me find what it hits (like the bracket on the far left that the window frame mounts to) and what holes it lines up with, if any.

I want to be able to sandwich the firewall between a engine-side backing plate and the pedal assembly itself.  Using the CJ2A tub "tailgate" panel, which is about 1/8" thick, I started with a basic template and cut out the plate.

I put it up against the engine-side firewall where I think it'll go, and then sprayed again with the primer to show me the holes.  So many.  The really large one is supposed to be for the master cylinder.  I'm thinking mine will mount hiring, but we'll see.

All cleaned up.

Now I had to take the pedal assembly apart, so I took a few shots of what it looks like for reassembly.

Pedals removed.  New little bushings on the way.

First round of scrubbing done.

VHT engine paint.

The Fairlane accelerator pedal bracket.

The hinges were next.  First I had to remove what was left of the original hinges.  The rod and the tube it rides in are all but fused.  Looks like a solid piece of metal, doesn't it?

A cutoff wheel made removal quick.

The lid isn't any better.

Here's the best I could find at Home Depot (yes, I could have gone to a specialty metal shop, but I wasn't in the mood).  The tube is obviously much larger than the rod.  But I have a plan.

Finally get to really use my vice.

Holding it in plan with the vice, I cut out about 35-40% of the tube.

Here's a better shot with it ready for the squeeze.  I placed the rod inside it and then crushed what was left of the tube around it until the rod was almost too tight to slide back and forth.

Of course I made two.

I had to cut off the lid pieces, as well.

Just sitting in place, they look really good.  My welding will take care of that.

I didn't think this part through, so I over-welded.

But then I cut through it to create the two-part hinge.  I was able to booger weld it better once it was off the tub.

A blurry shot, but that hides my mediocrity.

Primed, looking a little less ugly.

But they work and are properly aligned.

Another angle.  Not so bad, all things considered.