Pedal box and stuff

Need help from a fellow owner, something to air - discuss away!

Moderator: Contaminated

User avatar
Contaminated
Posts: 1270
Joined: Fri Feb 19, 2010 11:47 am
Location: Maidstone, Kent
Contact:

Pedal box and stuff

Postby Contaminated » Wed Feb 23, 2011 10:56 pm

Finally a bit of progress in relation to my pedal box and a few other bits and pieces.

Shiny bits waiting to go on.
Image

Halfway through fitting the new headlights. Makes the old ones look huge!
Image

Time for the pedal box. The problems I have are:

1. I have an aluminium bulkhead and floor - not ideal for mounting it!
2. The aluminium bulkhead is on the inside of the chassis rails, not the outside
3. I need to cut out the current floor mounted pedal supports and the brackets that hold the servo - which are a nightmare to get to with the angry grinder!

First I need to remove some of this.
Image

Halfway through cutting out one of the brackets by hand :evil:
Image

Brackets removed.
Image

Metal supports from original pedals removed. In doing so I had to cut through the floor, but it doesn't matter because I'll be replacing that part with steel.
Image

Next up I need to work out how to mount and support the new pedal box. The simplest solution would be to remove the aluminium bulkhead from the inside of the chassis rail and replace it with a steel bulkhead on the outside. This would also give me an exposed lower chassis rail to bolt the pedal box to. I can't do that without removing the engine and bodywork though because clearly the aluminium panelling and brakes were fitted before these :( What I decided to do was keep the aluminium bulkhead and fit a steel panel for support. I'll also fit one under the floor and use a bit of 1 inch box section to complete a frame for the new pedal box. After knocking up a cardboard template I got this made up at a local fabricators.
Image

Trial assembly - should work ok I hope!
Image

And from the rear.
Image

The next problem I've got is that the pedal box is designed to be bolted to the lower chassis rail, but you also need to drill holes for the clutch and throttle cables. That would be four 8mm holes in a chassis rail about 25cm long, which I've already inflicted a bit of damage on while removing the servo brackets. Looking at this there should be enough clearance to thread the clutch cable above the chassis rail through a redundant clutch master cylinder mounting hole. I may get away with the same on the throttle pedal, but doing so will reduce the travel of the pedal - so we'll have to see.
Image

That's it for now, might take tomorrow off and see if I can get a bit closer!

Dan
When I looked up "Ninjas" in the Thesaurus.com, it said "Ninja's can't be found". Well played Ninjas, well played!
Event joined by [Expand]

greenwoo
Site Admin
Posts: 9228
Joined: Thu Dec 03, 2009 10:34 am
Contact:

Re: Pedal box and stuff

Postby greenwoo » Wed Feb 23, 2011 11:01 pm

can you hurry up - i need mine doing ;)
Event joined by [Expand]

James

Re: Pedal box and stuff

Postby James » Wed Feb 23, 2011 11:26 pm

looking good mate :)
Event joined by [Expand]

daxmatt

Re: Pedal box and stuff

Postby daxmatt » Thu Feb 24, 2011 3:51 am

if you need any grinding done,get mark round
Event joined by [Expand]

greenwoo
Site Admin
Posts: 9228
Joined: Thu Dec 03, 2009 10:34 am
Contact:

Re: Pedal box and stuff

Postby greenwoo » Thu Feb 24, 2011 9:10 am

now that statement Matt could be taken two ways
Event joined by [Expand]

User avatar
Contaminated
Posts: 1270
Joined: Fri Feb 19, 2010 11:47 am
Location: Maidstone, Kent
Contact:

Re: Pedal box and stuff

Postby Contaminated » Thu Feb 24, 2011 9:19 am

greenwoo wrote:now that statement Matt could be taken two ways


Agreed, and either way I'm fine on my own thanks :shock:
When I looked up "Ninjas" in the Thesaurus.com, it said "Ninja's can't be found". Well played Ninjas, well played!
Event joined by [Expand]

Nogoingback

Re: Pedal box and stuff

Postby Nogoingback » Thu Feb 24, 2011 12:06 pm

Keep it up the clock is ticking.
Event joined by [Expand]

User avatar
Contaminated
Posts: 1270
Joined: Fri Feb 19, 2010 11:47 am
Location: Maidstone, Kent
Contact:

Re: Pedal box and stuff

Postby Contaminated » Sun Feb 27, 2011 6:12 pm

A bit more progress. All the metal cutting and drilling is done. Trial fitted it earlier and even before I fit the under-floor plate and with only three M8 bolts the pedal box is nice and solid :D

All I've got left to do is:

1. Order a new clutch cable from Burton
2. Fit a sleeve for the throttle cable to run through (to stop it rubbing on the chassis rail) - I'll probaly use a section of brake pipe
3. Fit the under-floor plate
4. Plumb the lines in and bleed the brakes.

Should be done very soon.
When I looked up "Ninjas" in the Thesaurus.com, it said "Ninja's can't be found". Well played Ninjas, well played!
Event joined by [Expand]

User avatar
locost220
Posts: 3521
Joined: Sat Mar 13, 2010 7:31 pm
Location: Lewisham South London
Contact:

Re: Pedal box and stuff

Postby locost220 » Sun Feb 27, 2011 6:31 pm

looks like great minds thnk alike hey Mark ( sort of ).
Locost book chassis, Under reconstruction :D :?
Event joined by [Expand]

User avatar
Contaminated
Posts: 1270
Joined: Fri Feb 19, 2010 11:47 am
Location: Maidstone, Kent
Contact:

Re: Pedal box and stuff

Postby Contaminated » Wed Mar 09, 2011 8:27 pm

Another update. Internal view of pedal box bolted down.

Image

Top down view - note new steel plate on the inside of the bulkhead.

Image

Bolts through bottom chassis rail. Note section of brake pipe that I will run the throttle cable through to stop it snagging on the inside of the chassis rail.

Image

And from below. Note new steel section of floor. Just needs plumbing in, a few lock nuts, trim down the bolts and sort that bit of rust on the chassis rail the camera flash has shown up!

Image
When I looked up "Ninjas" in the Thesaurus.com, it said "Ninja's can't be found". Well played Ninjas, well played!
Event joined by [Expand]


Return to “Car Related Discussion”

Who is online

Users browsing this forum: No registered users and 1 guest