Fender Well Modification:
The stock brake booster was too large and would have interfered with servicing of the fuel injectors and the Dual Ram manifold. A 7 inch dual booster and Corvette style master cylinder was sourced from a speed shop. It came with a 4 disc brake proportioning valve.
With the Senator pedal assembly moved as far to the right as possible, the drivers side fender well needed to be modified to clear the brake assembly.
A hole was cut in the fender well and a patch made.
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| View from inside the fender |
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| Pattern |
Used a shot bag to rough form the patch and then finally got to use a planishing hammer that I picked up on closeout at Harbor Freight for $25.
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| Forming the sheet metal |
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| Planishing hammer |
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Patch Panel in Place
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Fresh Air Intake:
With the stock heater removed a new way to get fresh air into the cabin was needed. A fresh air intake plenum was fabricated using 20ga. sheet metal. A rain baffle placed in the middle of it and drains added to its base. The plenum connects to the dashboards center vents. A rubber gasket will be added to seal it to the hood.
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| Side View |
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| Front View |
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| Side View |
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| Rain Baffle |
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| Fresh Air Intake |
Next up, constructing the firewall, installing the heater and building the transmission tunnel.
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