Bulkhead

The last month has seen lots of small steps towards completion of the front bulkhead. As usual, I started with a cardboard template - the bulkhead has to allow the steering column, clutch and brake master cylinder through it. I had a small panic when reading the latest IVA rules which stated that the fuel tank should be separated from the passenger compartment by a bulkhead which should not have any holes in it. This is difficult as there must be some sort of hole to allow the fuel pipes out! I phoned VOSA and spoke to a very helpful expert who said that what the rule wanted was to ensure that the fuel had a path of escape that would not cause it to flow into the cabin. Sorted!!! Anyway, the cardboard template wasn't a good as usual as the first attempt at making it out of steel wasn't very good! The bulkhead had to have a recess to allow the clutch pedal full travel, whilst also leaving room for brake and clutch pipes behind it. I went through lots of variations before I settled on the final, and simplest design. The recess for the clutch was made by cutting a piece of 50x50 box (and hitting it with a hammer) and welding it onto the sheet. The sheet was then trimmed to fit, re-trimmed, trimmed a bit more until it finally slotted in nicely. To finish off, I gave it a quick coat of weld-through primer so that it will stay in good condition! Next, I have to make a removable bulkhead for the passenger side that will allow removal of the fuel tank should it be necessary.