Pedal box: how much rust is too much rust?

[gordon415]

I'm sure the answer is "any."

 

I recently removed my carpets and spent many grueling hours removing the tar off the floor pans so I can install some new sounds deadener. I can see the light of day very clearly through several holes in the pedal box. While this did help provide some much needed light when I had my head down there removing tar, I'm sure this is not a good thing. 

 

Should this be replaced? Or go to town with Por-15? 

 

More info: there is no exterior foam insulation on the underside of the pedal box (but I just bought a replacement one from Blunt). A previous owner put lots of clear caulking and spray foam (wtf?) on the outside of the pedal box. This is not the only place I've discovered spray foam on my 2002. 

 

Here are some pictures. 

[kbmb02]

12 minutes ago, gordon415 said:

Should this be replaced? Or go to town with Por-15? 

 

Here’s one opinion: That rust to the right of the vertical support which holds the ‘pedal through bolt’ may be cause for concern; weak enough and left as-is, the bad scenario is you push the brake pedal and the vertical support tears / collapses. (At that point, you’re hoping your parking brake is fully functional.)

 

This is not intended to minimize the time/effort of fixing or replacing the pedal box - not exactly fun. -KB

[Mike G]

custom weight reduction, nice. That’s pretty bad, I’d start cutting and welding. If that’s not your cup of tea replace it and sell that dirt cheap to one of the masochists here who are into that sort of thing. 

['76mintgrün'02]

I'd say that is too much to ignore... or simply paint with POR.

@BarrettN is parting out a '76... maybe he has a pedal box for sale.

 

If you are up for a little metal fabrication and welding, it could be patched.

I don't regret repairing mine, but I am not sure it is a practical thing to do, unless you enjoy that sort of thing. ( I do   )

 

All you have to do is pull it out, take it apart, make a paper pattern, cut a patch panel and weld to shape, cut out rust by tracing patch panel, weld in panel, sand blast, prime, paint, rebuild pedal box. 

 

[andyleonard]

Both guys above have hit it.

 

If you are a welder, take it out, sandblast it and reinforce the right-hand bolt support...and while you're in there braze up the little holes or something. The holes are not your big problem. You REALLY don't want that cross bolt to tip under pressure.

 

If you are not a welder, get it out of there and replace it with a good shell - keep all your pedals and stuff - and replace any worn bushings and springs that look janky while you're in there.

 

You have 3 points of contact with your car: the steering wheel, your butt and your feet. Don't give away the feedback from one of them to save a dollar or two.

 

Plus the cost of the trouser change when the pivot breaks away.

 

 

[gordon415]

Thanks. That's a good point, although not what I wanted to add to the to-do list. But seems dumb not to whole I'm already down there. 

 

[halboyles]

4 minutes ago, kbmb02 said:

That rust to the right of the vertical support which holds the ‘pedal through bolt’ may be cause for concern; weak enough and left as-is, the bad scenario is you push the brake pedal and the vertical support tears / collapses. (At that point, you’re hoping your parking brake is fully functional.)

 

I'm with kbmb02 on this  If the rust weakens that vertical support you are going to need a lot more than POR15, as in, you are going to need welding skills.  If not, it might still impact the accelerator pedal hole on the right side.  So you might not be able to stop the car or you might not be able to stop the engine.  

 

But I would add the caveat that the parking brake is really only adequate to keep the car parked when it is already stopped.  High speed parking brake application might be a quick and unexpected lesson in why handbrake turns help rally drivers drift through tight corners.

[gordon415]

2 minutes ago, andyleonard said:

 Plus the cost of the trouser change when the pivot breaks away.

I'll buy some diapers until I can fix it ???

[andyleonard]

Ever wonder why amateur driving suits have puffy butts?

[gordon415]

@'76mintgrün'02 it's impressive how much PBR improves our lives, but I'm especially impressed with your workmanship. 

[stephers]

Just sent you a PM,   

 

Thanks, Rick

[Simeon]

Just as a point of comparison: any rust perforation within 30cm (1’) of anything ‘important’ (brake pedal, master cylinders, suspension mounting, steering components etc) is an instant fail on the UK MOT test. 

 

This would dedinitely fall fall into this category plus the repairs would need to be as well executed as @'76mintgrün'02

[BarrettN]

I haven't pulled the pedal box on my parts car, but I'll probably get to it this week and post pic how it looks if it's good.