D88-90: Firewall v2 + Unpowered Brakes

I haven't had a chance to post from the last few days in the garage, so here's a quick update. I've wanted to redo the upper firewall for the driver side since the first one went in. Here is my second go around. I think it turned out much cleaner. I also moved the mount for the steering shaft up a little bit to simplify the final weld and move the steering u-joint away from the engine mount.

After removing the brake booster, the master cylinder sat a little close to the firewall. I build a "shim" to move it out by about 3/8".

Here is the new firewall with everything attached. I'm so much happier with the way this version turned out.

With the brake booster removed, I had to shorten the push rod from the pedal to the master cylinder. Here is the shortened version.

Below is the brake pedal with the new push rod installed. Now I just need to figure out how to make sure that the brake pedal doesn't swing back and the push rod come out. This was all held in place by brake booster before. Oh, and I hope that I don't need that booster. Ha.

D87: Steering Column + Mount

Today I spent some time working on my new steering column. I wasn't thrilled with the first attempt, and kept thinking it was too weak. The drilled out 3/4" tube seemed too thin.

Here is my second attempt. I cut the end off the donor column which happened to be .47" on the inside which is close to the size needed for a 1/2"-20 thread. I threaded the end of a 3" grade 8 1/2"-20 bolt into this end. The smooth end would slide nicely into the 3/4"x.120 DOM that I'm using for the column. The smooth end had a little bit of slop, so I used a piece of paper to ship the bolt to keep everything tight and straight for welding.
Below are the two pieces assembled and then welded and ground. With both pieces .120 wall, and the joint being supported by a 1/2 bolt, I feel MUCH better about the strength of this design. I also plan on drilling a couple of holes on either side of the weld and then welding them up. I'm hoping this will add some torsional strength by transferring some of the load onto the bolt.
With the new column together, I need to check the clearance with the engine mounts. I got the engine back in and THANKFULLY everything fit just fine. It's definitely close, but I don't think the engine is going to shift side to side. In theory it'll more rotate which shouldn't interfere with the steering linkage.

Knowing the new column would fit around the engine mounts, it was time to get the drivers end mount built. I'm using a 3/4" steering shaft heim joint to attach the column to the mount. Below is the mounting hole for that heim. I cut a 1" hole in the 2"x1" tubing and used some of the 1" DOM from the a-arms inside.

I plan on adding at least one more piece to reinforce the mount.

I also played around with placement of the turn signals and ignition switch. I haven't settled on anything that I like yet.