Plugging rusty threads in the chassis
TL;DR if not plugged at the factory, do something
On the passenger side, a pair of unused threads become a rusty opening to the steel frame.
There is a pair on each side of the chassis but a single pedal box to use them. As the top of the passenger footwell collects rainwater that enters through the bonnet louvers, those holes are also splashed and the bare metal is rusting quietly.
We are talking about M8 threads, it did not take much thinking to fill them with a pair of stainless steel grub screws and a healthy layer of grease.
In order to better cover the opening, they were soon replaced by a pair of black nylon M8 philips screws with a large flat head. They were greased as well.
Reading what I've just written, it's likely that the water ingress in the passenger footwell comes from that junction between the space frame and the riveted cover. I might need to put some gasket in there too. And we both know it will end up with a carbon fiber lid.
After inspection and some wet experimentation, that plate is actually sealed with black silicone and no water comes in. Now I know where the water does not come from.
The panel is about 16cm wide and a bit less than 25cm long. A 20 x 25cm carbon sheet would be sufficient. Watching videos filmed at the factory very closely confirmed it is installed well after the skin is fitted around the chassis, actually after painting. Thickness of the pedal box lid is 1.8mm, I assume it's 1.5mm aluminium+powder coating on this side as well.
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