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Alternative and Low-Cost Pedal-Box
Version 2.0 12th June 2012 By Sylvain ROIG email@example.com See pictures of my Pedal-Box construction on my blog: http://vouchtroadster.blogspot.se/2012/05/pedalier1-pedal-box1.html http://vouchtroadster.blogspot.se/2012/06/pedalier2-pedal-box2.html
I want to apology for that. and I hope it is understandable enough.3design@gmail. If anybody wants to help me to put this guide in a better English. I can send all the texts by email for correction. I did my best to write this guide in the best English I could. and integrate them in a new version. Sylvain All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain. but I’m aware it should be full of mistakes.Important note about the language I’m French and not natural English speaking. Thank you.com .
This gives a “single-seater” PedalBox’s look (without the brake bias balance bar for dual master-cylinder use though. they should be 28mm diameter with 3mm walls. Of course. and this dimension is not used anywhere else in the car. If you don’t have any scrap of that. I started the design from the book’s Pedal-Box. lengths. This alternative Pedal-Box is just an adaptation of the book’s PedalBox to straight shaft pedals.com . So the idea was to make the pedal shafts from 25mm square section tubes. the last stage of the chassis builing. Making the Pedal-Box is. A that stage. and so on. which is an extra cost I wanted to avoid. The book’s pedals shafts could be cut by hand. as an alternative of the book’s Pedal-Box.3design@gmail. which is closer to a single-seater than to a saloon car. in order to keep the cost of the Pedal-Box as low as possible. and what technical choices I had to do and why. All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain. Here are some explanations about this alternative design. Straight Pedal Shafts The main goal of re-designing the Pedal-Box of the Haynes Roadster. it might be important to know why and how I re-drew the PedalBox. Same problem with the pivot tubes: according to the book. but I guess with a very poor result. Making the pedal shafts from straight tubes rather than from 3 and 5mm plates implies that you can not chose the shape: the pedal shafts will be straight. it is a shame to buy a full length of tube for cutting only 3 x 30mm long pieces. but the brake pedal could be easily adapted to use one if you wanted). and the pivot tubes from 20mm round section tubes. as well as 19mm (20mm in my case) round section tubes if you made the back panel as in the book. This “single-seater like” Pedal-Box is also very well adapted to the driver’s position in the Roadster.Introduction Before starting the construction. was to use leftovers of tubes from the chassis building. pivot point heights. according to the book. so it looks like most of the builders choose to order them laser cut. and not a completely new design that would have required engineering skills I don’t have. and I tried to keep the new one as close as possible to the original one. So I respected pedal ratios. the workshop is full of 25mm square section tubes bits.
I decided to make brackets that will allow to get a longer stroke if needed. stroke This was achieved by moving the pivot point forward. but keeping the original pivot point as well: the hole the closest to the back plate keeps the same pivot point as the book’s Pedal-Box. and the hole the further to the front keeps the position of the books pedal foot pad when leaning 20° forward.com . stroke. The distance between these 2 holes is 26mm. The stroke was not an issue for the brake and accelerator pedals. but I kept the same hole pattern for the 3 pairs of brackets.First because I realized that the stoke of the clutch pedal would be shorter with the straight shaft than with the book’s pedal. so in between I had room to add an intermediate hole which gives an extra set-up option.3design@gmail. Book’s clutch pedal in normal position Straight shaft clutch pedal in normal position Book’s clutch pedal max. stroke Straight shaft clutch pedal max. in order to keep at least the same max. The result is a fully adjustable Pedal-Box: you can find the ideal pedal positions combination that suits your driving style or needs. All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain.
Clevis and Cable attach points The other adaptation I had to do concerns the attach points of clevis and cables on the pedal shafts. For my built. Also.. But if you have the right sources. we will need to remove part of the back face of the tube to allow the cables/clevis to move freely when the pedal moves. so I opted for top-hat bushes (bushes with flange). I don’t find them particularly nice. but a with tubular pedal. All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain. I’m quite happy with the result as it does not only stop the pedals from moving forward. I didn’t find bushes of the right dimension (except at a very prohibitive price!). I thought I could just weld an M6 nut on it. you can find the right bushes (I know some nylon ones exists with these dimensions) this will be time saving for sure. and nicer result! Forward Stops The other elements I haven’t kept are the forward stop plates of the book’s Pedal-Box. A « plate » pedal just needs a hole in it to fit cables/clevis with a short bolt.3design@gmail. but it also allows to adjust the angle of the pedal quite accurately. in order to use an M6 bolt and a lock-nut as forward stops. and I had to make them myself. It doesn’t sound the best to me. which makes the edges of the steel tube being in direct contact with the steel brackets.. Top-hat bushes The book says to use a 30mm long pivot tube with a simple cylindrical bush inside.. As the attach point is inside the tube. it avoids to drill another hole in the Roadster’s floor as the books says to do. in order to get a soft and sliding material between the tube and the brackets. it is different. cutting.com . So. drilling and carving them into a PTFE rod. for the brake pedal. having a 25mm wide face in the front of each pedal shaft..
3design@gmail.BRAKE AND CLUTCH PEDAL PAD R=12.5 137 Diam 8 21 25 Diam 20 10 31 41 20 35 31 R=10.com .8 238 View A 234 150 R=10.5 35 Curve Radius =127 Angle = 53° Bent 117 Flat BRAKE 6 BRAKE View A 84 97.5 M6 nut M6 nut 4 25 10 25 Remove Weld with 1mm gap Round section Diam 20 x 2 wall tube L=25mm All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain.5 Curve Radius =127 50 Angle = 45° Bent ACCELERATOR PEDAL PAD 100 Flat R=12.
5 10 Diam 8 29 14 21 55 69 M6 nut M6 nut 25 25 Weld with 1mm gap Round section Diam 20 x 2 wall tube L=25mm All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain.CLUTCH 6 CLUTCH View A 84 97.8 View A 234 Diam 20 150 20 20 133 Rfirstname.lastname@example.org .5 M6 nut M6 nut 10 Diam 6 38 48 24 10 21 Weld with 1mm gap Round section Diam 20 x 2 wall tube L=25mm 25 25 ACCELERATOR 6 ACCELERATOR View A 84 101.8 View A 234 137 150 Diam 20 20 20 R=10.
email@example.com .Brake Pedal Equipment Clutch Pedal Equipment Padal Top Hat Bush Dimensions Padal Top Hat Bush Dimensions 20mm 20mm 2mm 12mm 8mm 2mm 12mm 8mm 16mm 16mm Front Stop Bolt Front Stop Bolt M6 Lock-Nut Clevis Assembly M6 Lock-Nut Clutch Cable Bolt Assembly (To Fit Ford Capri Clutch Cable) Welded M6 nut Welded M6 nut M6 x 35 Bolt M8 x 40 bolt (25mm non-threaded) M8 Nylock Nut M6 x 35 Bolt M6 x 40 bolt (25mm non-threaded) M6 Nylock Nut Clevis (8mm diam Axis) M8 Washers M6 Washers Accelerator Pedal Equipment Padal Top Hat Bush Dimensions 20mm 2mm 12mm 8mm 16mm Front Stop Bolt M6 Lock-Nut Clevis Assembly (the throttle cable will have t be adapted to the clevis) Welded M6 nut M6 x 35 Bolt M8 x 40 bolt (25mm non-threaded) M8 Nylock Nut Clevis (8mm diam Axis) M8 Washers All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain.
16 Diam.8 40 55 60 55 40 All 1:1 scaled drawing available in PDF and SVG formats on request at: sylvain.8 Diam.8 Diam.firstname.lastname@example.org Diam.8 150 49 170 Ford Sierra master-cylinder only (diam 41mm) 49 125 Push-rod axis 90 Diam.8 Diam.com 30 20 .8 50 Diam.BACK PLATE 29 70 134 70 268 70 29 Diam.8 Diam.8 Diam.16 PLATE H1 27 If CP16 is 1mm thick 250 29 If CP16 is 3mm thick PLATE V1 22 250 PLATE H2 250 Diam.8 Diam.
this distance was 31mm (25mm pedal + 2x3mm flanges) 81 60 Plate H1 Plate V1 9 18 9 49 85 85 49 Plate H2 All 1:1 scaled drawing available in PDF and SVG formats on request at: email@example.com R=15 R=15 13 13 Diam 8 69 CLUTCH PEDAL BRACKET 23 105 19 15 R=15 30 BRAKE PEDAL BRACKET 13 13 Diam 8 80 15 R=15 R=15 13 13 Diam 8 88 ACCELERATOR PEDAL BRACKET 21 114 21 Distance between 2 brackets will depend of the thickness of the bushes flange. On my pedal box.com .
8 Diam.16 Round section Diam 20 x 2 wall tube 16 20 20 Back Plate Plate H1 (27 or 29) Plate V1 77 71 84 Diam.8 Diam.8 Plate H2 9 9 49 85 85 49 Back Plate Round section Diam 20 x 2 wall tube 70° 84 13 13 25 77 13 13 81 Plate H1 Plate V1 25 71 13 13 18 60 27 or 29 53 Plate H2 All 1:1 scaled drawing available in PDF and SVG formats on request at: firstname.lastname@example.org Diam.com .
0 France License.com Plan for your brake lines now! Visit my website: http://sites.org/licenses/by-nc-sa/3.Rear Stop Bolts Installation Brake Pedal Installation M8 x 60 Bolts (completely threaded) M8 Washers M8 Nuts M8 Nylock Nut M8 Washers M8 x 50 Bolts (35mm non-threaded) Clutch Pedal Installation Accelerator Pedal Installation M8 Washers M8 x 50 Bolts (35mm non-threaded) M8 x 50 Bolts (35mm non-threaded) M8 Washers M8 Nylock Nut M8 Nylock Nut This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.com/site/hydraulicforkitcars/ . Mountain View. For any information regarding this work. USA.0/fr/ or send a letter to Creative Commons. Suite 900. California. 444 Castro Street. To view a copy of this license.google. visit http://creativecommons.3design@gmail. please send me an email: sylvain. 94041.
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