Page 1 of 3

Pedal box and stuff

Posted: Wed Feb 23, 2011 10:56 pm
by Contaminated
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

Re: Pedal box and stuff

Posted: Wed Feb 23, 2011 11:01 pm
by greenwoo
can you hurry up - i need mine doing ;)

Re: Pedal box and stuff

Posted: Wed Feb 23, 2011 11:26 pm
by James
looking good mate :)

Re: Pedal box and stuff

Posted: Thu Feb 24, 2011 3:51 am
by daxmatt
if you need any grinding done,get mark round

Re: Pedal box and stuff

Posted: Thu Feb 24, 2011 9:10 am
by greenwoo
now that statement Matt could be taken two ways

Re: Pedal box and stuff

Posted: Thu Feb 24, 2011 9:19 am
by Contaminated
greenwoo wrote:now that statement Matt could be taken two ways


Agreed, and either way I'm fine on my own thanks :shock:

Re: Pedal box and stuff

Posted: Thu Feb 24, 2011 12:06 pm
by Nogoingback
Keep it up the clock is ticking.

Re: Pedal box and stuff

Posted: Sun Feb 27, 2011 6:12 pm
by Contaminated
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.

Re: Pedal box and stuff

Posted: Sun Feb 27, 2011 6:31 pm
by locost220
looks like great minds thnk alike hey Mark ( sort of ).

Re: Pedal box and stuff

Posted: Wed Mar 09, 2011 8:27 pm
by Contaminated
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