I continued to design the remainder of the extension. Rather than put another piece of flat stock on the bottom of the extension to "build some height" on the bottom of the extension, I decided to use a piece of half-round stock. My reasoning behind this was to have my foot "roll" over the piece of half-round stock in order to use my ankles to pivot to press on brakes. Well that's the theory anyway.....willl be a while before the theory gets tested though :-)
I bought a short length of 1" aluminum bar stock and cut it the length plus a little for blending later when I attach them to the extension in order to profile them with the profile of the extension.
So I cut the bar in half with the saw and then machined the surfaces flat and made the half-rounds the same thickness which was a little over 7/16 ths. Next I clamped the half-rounds to the extensions and drilled the holes to attach the half-round bar stock to the pedal extension. I had to be careful not to drill to deep to NOT break through the other side of the half-round foot rest.
