While going the box of parts from the car which wasn't much looking for the the rubber isolators for the heater box which weren't there I pulled out the pedal pad set which is designated for a focus ST. With very minimal mods there for on escort pedals, as I only have the throttle pedal here ( the others are at the anodizer) , I decided to fit the pad

Simply slide the rubber grip over the pedal and screw it up

Next is to secure the stainless plate over it

And this is it ready to go


Still assembling the heater box adding density foam for sealing, I'll show this once done

Still carefully building the heater box now it's all dry I can attach the plastic air deflectors. Being pedantic I didn't use the standard Philips screws, instead went for (you guessed it) rivnuts and stainless cap heads, yes I know overkill but it looks cool!


These little ducting parts I made on the 3D printer after a few hrs design. I did try to scan and mesh but couldn't get a good full scan so home designed it then mirrored for both sides , printed in petg for heat resistance

Waiting for the 7in thermo fan instead of the factory cumbersome fan, so I can get the heater
ready to install

After noticing the 4x standoff mounts for the heater on the car has only 3 speed clips, time to bring out the rivnuts again to make the mounting a lot more solid. I have ordered rubber isolators designed for motorbike fairings, they come in packs of 10 so I bought 2x packs for only $6, their be here next week.

I did have a MK2 heater core to go in the matrix but noticed a leaky fin and a tube was loose, I tried to Tig it back together but ended up blowing holes everywhere (😞) , oh well, I do have others and went for the mk1 core, I cleaned it up, rinsed it out and pressure tested with air and soapy water at about 20psi and it was good.
Next was to make a pocket for it to live in for the rest of ever. I used that layered foam that is cut to the shape of the item for safe transport . Anyway a lot of trimming and contact glue I made a good air tight seal.

Then made a full lid side insulation before the cover went on

And the final pic is all bolted together except the fan which is still in transit

Here's 1 for Part Time, a pic of 1 of my welders and trolley , the Tig is on the bottom shelf while the dry weld (gasless) sits on top. An empty 15kg spool cut into 3 so I can wrap the cables strong without binding. The other side has tubes to house Tig rods of different types .


Yes Deano is also gas powered..!

man, thats too neat, esp the exhaust flappers for your TIG sticks.
Mine are still in the shipping box, oh well, thats a bucket list for next year, learn to TIG.
 
 
Can I suggest once you do start taking the coupe on the show circuit, maybe some mirror tiles on the carpet?
Just to show off the colour coded, 12V fanned, rivnutted  area 69  work of art heater? 
What colour are you going with the heater ducting tubes? Black seems a bit of a let down?

Haha, I copied Welding Tips n Tricks a few years ago, he also suggests to have the bottle lay flat (torpedo style) which makes sense as it needs mixing up if left standing for a while, something I never knew..
Smart thinking but I'll pass on that one !

The heater saga is nearly over, I just spent this rvo on making cable clamps as all mine was broken or missing , obviously used rivnuts again, only cause I have 1000s of them and 1000s of cap screws from M3 to M6, anyways I simply bent some alloy flat to pinch the outer cable

And this is the heater control

Had a cable clip missing on the lever, the little black bit disintegrates over time so used another rivnut so I can screw the cable down tight .

Marty,
Should've put a call out for the clips that lock the outer cable to the side of the heater box and the lever ones.
Got a few spare floating around.

Yeah iw was going to ask but couldn't wait for replies, my method ended up being way better anyway.
All I did today was mount the cables and lock in place after adjusting the levers so it works proper good now, no binding etc.

Had a parcel arrive this morning, it was the thermo fan I been waiting on to almost finish the ongoing heater box story. The fan needed it's blades clipped about 15mm , easiest way was put the motor in a vice and power it up then cut with grinder and flap disk to balance up . Next was make a ring for the fan to sit inside as I'm not using the thermo housing it came with. Folded a 90° and used a stretcher to radius it into a circle.


Then it was mount the fan inside and use more rivnuts to mount everything solid


I hope to not post any more on this as I'm over it! The last pic will be it installed and will move to the next parts.

Tick that off, whats next?
 
You have a CAD room.?