Pedal box

As supplied by AK. It is a basic metal frame with a shaft running through it which pivots the brake and clutch pedals.
I'll have to 'fess up and say I dropped the box and put a small dent in the side of the box, nothing that would stop it working ok. When fitted to a temporary wooden frame to test and bleed the clutch, the shaft collapsed rendering both clutch and brake pedals useless.
The shaft is fitted to the left side of the box with two tack welds. I believe that these were weakened when I dropped the box and the shaft being only just located in the hole of the box slipped inside so the pedals collapsed.


The fix for me was to strip it all out and have a flange fully welded to the end of the shaft. This will prevent it ever collapsing inside again. I'm going to do this anyway on the next build, or ask AK to do it!

Ideally I would have had a new, slightly longer shaft made but the original one still fits ok as long as we have a small collar on the other side where the retaining nut is fitted. The nut is secured with a spring washer and thread lock.

When testing the clutch pedal, I found it was not quite in line with the push rod for the clutch master cylinder. It operated ok for most of the travel but became tight towards the end of the travel when the pedal was fully depressed. As I had it stripped down I removed 2mm from the width of the clutch arm boss which the shaft sits in. This allowed for some spacer washers to move the clutch arm to the right which then properly lines up with the cylinder push rod.

Next is the throttle pedal. As standard it is just located with a bolt that cannot be tightened as it would seize the pedal. It needs a proper sleeve to rotate around which can be properly bolted in place.
I obtained some 8mm OD tubular steel, cut to length so it protrudes just 1mm from the pedal boss.

We can now assemble it onto the pedal box, properly tighten the nut. The throttle pedal is now more secure and has less lateral play in its movement. However if we tighten too much the pedal will have interference and not move smoothly. The nut needs to back off slightly. It is a nyloc, but even so, best secure it with a lockwire



Now we can assemble the box into the footwell and fit the master cylinders on the engine bay side.

But, before we do that, if you have a cable throttle with a Jenvey throttle body, get the cable fitted now or it will be a very difficult job later on. See here on fitting the cable.

There doesn't seem to be a lot of room to top up the brake fluid!