Footbox Aluminum - Passenger Side

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Major System Category: Chassis
Task: Build the passenger's foot box
Parts: All parts were attached to chassis on delivery
Prerequisite Tasks: Inner Wheel wells
Additional Costs: N/A
Time Requirement: 4 hours
Date Started: July 13, 2012
Date Completed: July 13, 2012
Consideration: If you are installing, stop now and go to back of the manual and start installing the air conditioning. The evaporator unit must be installed before the passenger foot box is completed.

The passenger side foot box seemed easier to put together than the driver's side. The pieces are different, and there is no fitting around the pedal box. This was pretty straight forward.

This the front wall. Orientation facing forward looking from the passenger area of the cockpit. More than half of this piece connects to the outer wall. The outer wall is not installed, but when installed closes out the right side of the photo.

Once you close in the foot box with the outer wall, it is just a matter of drilling the holes and popping the rivets. I caulked everything heavily with the silicone and sprayed every seam with Plasti Dip. 

You can see the diagonal seam between the front wall and the triangular  shaped panel. This panel serves as an anchor between the inner wall and the front wall. It uses a similar (albeit simpler) interlocking tab concept as on the driver's side. Orientation is facing forward from the passenger cockpit. (You can see the Boxster sitting outside on the driveway.)

I ordered a can of Eastwood's bruashable seam sealer today. This is to address the gaps I see on the underside of the car as well as the some of the areas where the panels have tiny pin pricks. The seam sealer is not supposed to sag, harden or crack. It drys to a dark gray color. I plan to apply a couple of coats, then spray Plasti Dip as an additional layer.

This is the inner wall. Unlike the driver's side, this is one piece. It is  much easier to work with.  Orientation is looking forward from the passenger cockpit area.

The items I am beginning to think about are the sound proofing and heat shield products. Once I get to the point where I have the foot box areas sealed and the floor finalized, I want to put the appropriate materials down to solidify the chassis and reduce the rattle effect.

I call this the funny little connector piece. It is basically there to give the inner wall  an anchor. Orientation is looking from outside the passenger side towards the tunnel.

I need to evaluate  whether I should work on the steering linkage and pedal box prior to mounting the front suspension. Since I am waiting on parts for the shock mounts for the rear suspension, I don't see the benefit of having half the car up on wheels and other half sitting on jack stands.