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