I'm currently looking at pedal designs and it got me wondering what I should use for the footwell bulkhead that the sierra master cylinder will bolt to. I have some 2mm aluminium and wondered if that would be okay as there will be a lot of pressure put on it by the brake master cylinder poking stick. Damn whats that thing called again!! Thinking shall I reinforce that area with some 19mm sqaure or 3mm steel plate.

The thingy is called a push rod. I'd use 2-3mm steel plate for the bulkhead, especially the bit around the pedals. Maybe with a reinforcing strip for the cylinders to bolt to.

IMO aluminium wouldn't be stiff enough, plus it would have to be fixed by bolts or rivets, which wouldn't be as strong as fully welding in place.
I used 2mm steel stiffened by cross bracing. SVA tester looked closely at the master cylinder with brake pressure on & off to see if it moved.

3mm steel in mines. I reckon that over time the ally (even if braced) would work harden and crack through the bolt holes.

Push rod. Thats the one. (You wouldn't believe I have qualifications in engineering would you!) Okay then, good point about the work hardening and cracking, steel it is then.

No reason you can't use ally for the passenger side though. I've used 3mm steel, but even that needed bracing to satisfy SVA bloke.

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Originally posted by mistergrumpy
the brake master cylinder poking stick.

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Yep. Thats what I have in mind. Don't wanna be paying main stealer or scrappie for summat like that. Cheers.

file the end to a "roundy blob" though or itll stick at all sorts of angles