Pedal alterations

Time for surgery on the clutch and brake pedals. The originals are designed to fit around a brake servo, hydraulic clutch and a small footwell. There are various angles on the metal that just aren't needed. They're also a fair bit too long.

First thing, chop everything up. Here's the pedals in bits;

The gas pedal will stay as it is, so that is put aside for now. I'm working off the same measurement as for the Sierra brake pedal. The Sierra clutch pedal is cable operated so is lifted off the floor, but with both clutch and brake being hydraulic here it means the hinge is at the base (hence both being the same length as the Sierra brake pedal). So both pedals will be 191 mm from the edge of the outer bush to the centre of the pedal plate. A decent cut on both to keep the profile tidy, nice and simple. I also screwed both the plates on to a piece of wood, to keep the angle correct and have them at the same length. It made it easy to measure from the bush to the wood, and to keep everything at right angles.

A bit of welding leaves me with this;

The metal used for the pedals is quite beefy, but with the welder turned up high I'm happy I got penetration. It certainly took long enough to cool down (as evidenced by a very sore thumb).

Once things were cool enough to take apart, I was left with this;

A quick boot measurement had the pedals at just right place, which is fantastic. One last trial was to replace the aluminium faces;

Unfortunately they can't stay as they are because the IVA requires a permanent non-slip surface, either rubber or skateboard tape. Tape will be cheaper.

The holes for the pushrods are in the same place as before so hopefully things should still work well. 

Tomorrow will be the brackets and holes for the master cylinders.