Figure 1: Dead pedal in situ.
This project was cheap and easy, and pays great benefits in driver comfort.
I used 1/4 inch, high-density fiberboard (aka Masonite) for the front and side pieces, and scrap plywood to join the two pieces
together and to anchor the angle brackets. All wood screws are countersunk.
Figure 2 shows the dimensions (in inches) and shapes of the pieces. The only critical shape is the curve of the side piece,
which needs to match the contour of the firewall. (Full-scale outline of side piece here.)
Create a cardboard template to check the curve before you cut wood.
Assembly details can be seen in Figures 3 and 4.
I routed out the front piece to allow the brackets to fit flush; painted the assembly with Plasti Dip spray paint;
and covered the front piece with non-skid tape. The assembly is supported by its right edge, and on the left side by a plastic panel. The
brackets simply hold it in place.
Ursa Minor has developed a
very nice ready-made version,
available in plastic or carbon fiber.