Pedal Cluster Removal Headache

[PWRMKR58]

I have 1956 Bug. Who knows who replaced the floorpans or anything else on this wreck. My hands are full just trying to make some corrections to get the car on the road again.
The body is now off the pan. The pan is a mess. I have some work to do to correct the sloppy job. The heater channels are going to be replaced. Rust both front and back. Some rust both before and after the channels needs to be addressed as well.

The forward pedal cluster 17mm bolt snapped off flush with the cluster. The bolt was seized in the cluster. I was able to drill it enough to pull the cluster away about a half an inch but it is hanging up on something inside the tunnel. I checked the clutch cable and I don't think that's it. So I removed the clutch and brake pedals from the shaft. The shaft slides all the way in to touch the right side of the tunnel and spins freely like the cable is off. The cluster is still hanging up and won't let me pull it out more than a half an inch. A half inch of that forward stud is still in the tunnel. I think the weled nut is no longer welded and will get addressed but...
With the clutch and brake pedals detached shouldn't the housing just pull out?
What am I missing? I don't want to cut the tunnel.

I did a few internet and Samba searches and found nothing. Wronge wording?

Thanks for any help.

[VW_Jimbo]

Can you pull the pedal assembly away from the tunnel, the 1/2” that you mention, and get a tool in there to cut the bolt? That is how I would do it.
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[PWRMKR58]

I can pull the cluster out just to where the bolt is snapped off. I was hoping to keep as much of it as I can to get a grip on it, and maybe break it free, once I get the cluster out. I need to get some dremal grinding wheels for that. All my other stuff it to big.
With some of that bolt gone, am I supposed to twist the cluster to get it out?
Note: drilling the center out of the bolt was a breeze. Like it was pot metal or some such junk.

[esde]

you do need to tip the assembly so the clutch hook clears the hole in the tunnel, but as you have the clutch shaft pushed in I think you aren't even there yet.
I'm suspecting that whatever shoulder of the bolt you drilled is still hanging up inside the hole of the pedal cluster. Perhaps try pushing the pedal housing back tight to the tunnel, and have a go with the next size up drill bit?
And, I would not be so concerned with leaving a stub of the bolt to grab. Once the pedal cluster is out of the way, you will have plenty of access to center drill the bolt, and carefully clean up and chase the threads. If the bolt broke it needs help anyway..
_________________
modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that.

[PWRMKR58]

I cut down the bolt some. That didn't help. So to hell with it and I pried it out. Come to find out it was hanging up on the shoddy pan job.

[PWRMKR58]

And on to the next challenge.

[VW_Jimbo]

Now weld a nut on the end of that and twist it out!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[my3bugs]

heat n quench a few times then oil n maybe the vice grips ? dont want to shear it off .

i was scratching my head here , glad you got it out !!!

[PWRMKR58]

Thanks for the replies.

Vice grips and kroil got 'er did. A nut and mig was sitting on the side, waiting...

The pan has got bigger problems. I'm not going to redo it. So I'll work around it and try to make it stronger.

[VW_Jimbo]

Nice job! Based off of that odd spot for rustyness, is it safe to assume there may be a wee bit more flaky areas?
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[PWRMKR58]

The pan itself is...ok. It looks like PPO did a half ass prep job and slapped the pans on top, then did a half ass weld job and used way to much sealer. They placed the rusted body on top and it lookes like they sold it off. It sat in PO garage before I paid to much for it.

I just started getting into the whole project. I'm not in a hurry and I am not looking to completely restore the car. I want to drive it on nice days and just enjoy the old girl, on the road.