Here’s a big project that spread out over a number of months. I’m aggregated the photos here and attempted to make them tell a coherent story.
The cluster as a whole can be adjusted forward and back for drivers of different heights. The gas pedal is adjustable for foot travel, throttle cable travel and left/right position. The brake pedal height is independently adjustable, and brake bias is adjustable from front to back. The hydraulic clutch pedal is also independently adjustable for height.
Many of the original pieces were laser cut from steel, then bent and welded to form the complex shapes required. Some of the bushings were CNC turned, but most were made by hand. The master cylinders, brake bias adjustment cable, and the nuts and bolts were purchased, with everything else custom made. This includes the brake bias adjustment assembly, which forced me to learn how to cut threads on the lathe. It’s not as easy as it looks. Take a look at the brake bias adjustment bar– it has three sets of threads independently cut on a manual lathe, three diameters, two snap rings and a threaded hole. Good fun! Due to changes in the steering rack mount, the main pedal bracket had to be widened as you can see in the photos.
Laser cut parts arrive
Laser cut gas pedal parts before welding
Gas pedal parts clamped for welding. I like clamps.
Clutch pedal clamped for welding
Clutch pedal after welding and grinding
An early trial fitting
Testing fit inside the frame
Widening the main bracket
Finished main bracket
Lots of parts in primer now fitting together
Black epoxy paint
Finished except for brake bias assembly
New Chinese calipers: 2″ = 51.9mm LOLWUT?
Milling part of the brake bias adjustment bar assembly
I received my second batch of laser-cut parts, this time from a new supplier that has some more reasonable aluminum. They did a reasonable job, but man were they slow. It took three visits and more than two weeks to get a quotation, then I forget how long to do the work. Then when they were finished, I had to call them to find out. This is Thailand.
The parts are cut from both steel and aluminum of several different thicknesses, and include the radiator and oil cooler mounts, differential mounts, some engine mounts, the entire pedal cluster, parts of the steering column, chain tensioner, nose mounts, steering rack mounts, steering column mounts, lap belt mounts, chassis side panels, seat panels, the firewall, fuel tank, and even an idler sprocket.
Laser-cut panels including sides, seat and fuel tank