Very nice job. Those kinds of parts always seem so simple when you first think about making them and then take on impressively complicated design attributes as the project moves forward. Your design and finished work product is quite impressive!
While I can appreciate the fabrication of individual bottom and side pieces that are welded together to create the pedal box, did you consider making the box out of a single sheet of metal?
The approach would mandate starting by laying out the floor dimensions and making square cutouts for the four sides you would bend upwards in a brake. After bending the sides upward you would bend the flange along the top edge on each of the four sides. Now you would be ready to weld the four corners and the foot box shape fabrication would essentially be complete.
FWIW I didn't think of this approach, I'm not that good. A friend of mine, who is a sheet metal fabricator, that I had asked for help in building my
oil pan, looked at my
oil pan design (which I did the same way you did your foot pedal box) and asked me why I wanted to do this the hard way?
He then sketched up the 'easy way' on his MasterCam software to show me the route I could have taken design-wise. Here is a pic of the pan before welding the rounded corners in;
And this is what it looked like with the flange, trap door baffle and windage tray mounts in place;
Less time spent welding and a more robust finished product, for when I screw up and bounce it off something it should not hit.
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