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Old 03-29-2012, 02:24 AM   #111
markeb01
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Join Date: Feb 2007
Location: Spokane Valley, WA
Posts: 8,356
Re: Markeb01 Build Thread

More progress today on the gas pedal project. Here’s a photo sequence showing what’s been achieved so far:

This was taken yesterday before anything was taken apart:



Today the pedal assembly showed up:



The upper chunk was quickly unbolted and the trusty Dremel tool was called on to slice off the attaching bracket, even with the top of the plastic firewall anchor:



After further study I could find no reason to retain the ear on the upper left side, so it was sliced off and the remaining part angled to more closely match the other side:





Early test fittings indicated the right side of the plastic mount should be ground flat to match the angle of the firewall. This picture is out of sequence because it shows all three mounting bolts, but it’s the only one showing where the plastic mount was modified:



The complete assembly was test fit numerous times looking for the best fit at the firewall, the most comfortable pedal position, and level alignment. (Some of the pictures appear to lean to the left, but that’s because I didn’t have the camera level). Once the location was established, the upper right hole was marked with a 17/64 transfer punch (the next size up from ¼”). It was a tight slip fit to keep alignment accurate. That hole alone was drilled to ¼”, and the complete pedal assembly reattached to the firewall. This allowed a precise final alignment before marking the other two mounting holes.

With the pedal where it belonged, the top of the bell crank needed to move about ½” to the left. It was clamped in the bench vise at the point indicated by the arrow, and given a gentle nudge with an 18” adjustable wrench:



Bolted back in place, the upper cable hole was marked with a 5/32” transfer punch directly through the cable restraint bushing.

And finally the cable hole was drilled out to ½”.



Tomorrow I’ll get started filing the hole square.

After cleaning up the garage, I headed over to dinner with my machinist son. He whipped up a block off plate the same thickness as the former pivot plate:



And as a final touch he glass bead blasted the parts to be painted.



More to follow.
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Last edited by markeb01; 04-01-2012 at 01:27 PM.
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