AU XR Cracked firewall above pedal box

[jeffb]

This morning started off with a little rain, backing out the driveway I felt water dripping on my foot. After some investigating I have found that the pedel box has cracked the top of the firewall.

When depressing the brake the whole area flexes, so I can see why it happened, it is a really poor design.

I have searched and can see other people have had the same problem, but cant see what people have done to fix it. I am thinking I will have to take the dash out, drill out the cracked spot weld and weld some plate in there to stregnthen the whole area. I may as well do the clutch at the same time (its not cracked yet tho)

Has anyone had to do this? and pics on the fix? any tips?

[philstoj]

Mine was just a hole in the exact same place, the blasted crappy spot weld, and all i did to fix it was to use some urethane to seal it.

[jeffb]

I have done that just to stop the water getting in, but it needs to be fixed properly as it will only get worse over time.

[rob_liss_lms10]

I used 2 part " stronger than metal " epoxy for mine. The epoxy has metal fillings or something in it. Smear it on and let it dry. worked a treat, haven't had a leak again.