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Bias pedal boxes - mk2 + mk1 - FINISHED

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Paul Dunstan
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Re:Bias pedal box - mk2 2012/01/05 23:19:42 (permalink)
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You have PM

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Paul
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Paul Dunstan
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Re:Bias pedal box - mk2 2012/01/22 17:37:19 (permalink)
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Hi All
I have had some good interest in my cable clutch interpretation of the works style pedal box along with some very pleasing comments - so thanks guys
With that in mind I have done some investigation into how to adapt the hydraulic clutch to my pedal boxes - and here is the early result.
I have modified the OEM pedal to accept a 6mm section to connect to the clutch cylinder clevis. This additional section incorperates the OEM pedal pivot point as in the same way as the brake pedal and will be boxed for maximum strength. The modified pedal will also retain the OEM pedal stops at each end to prevent the master cylinder bottoming out.
Here are some pics of the progress thus far and the OEM pedal I started with. I have also altered the front plate to include the clutch master cylinder (yet to be bent).
post edited by Paul Dunstan - 2012/01/22 17:54:31

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Paul
#32
Matt75
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Re:Bias pedal box - mk2 2012/01/23 13:05:41 (permalink)
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You rock!
 
Looks great as always.
 
Matt

 
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#33

Paul Dunstan
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Re:Bias pedal box - mk2 2012/01/23 22:29:13 (permalink)
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Thanks Matt
One step closer - final assembly to check my measurements / alignment before tacking together.
All looks good so I'll hopefully have it all welded over the next week.

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Paul
#34
barney
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Re:Bias pedal box - mk2 2012/01/24 07:38:36 (permalink)
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looking the goods paul!! i think i should pull my finger out! or i'm gonna have a box full of parts and a car no where near ready for any!!
 
Atleast seeing all this work is giving me some inspiration!
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Paul Dunstan
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Re:Bias pedal box - mk2 2012/01/24 21:42:29 (permalink)
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barney 

i'm gonna have a box full of parts and a car no where near ready for any!!


Gee - I certainly know how that feels
Latest batch of pedal boxes well underway


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Paul
#36

Paul Dunstan
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Re:Bias pedal box - mk2 2012/01/26 17:37:21 (permalink)
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Hi Again
Not a great amount to update but I've tacked together my hydraulic pedal box shell along with the clutch pedal.
I used the same pedal pivot to clevis relationship as the brake pedal as this maintains the minimum deviation from the horizontal C/L plane of the master cylinder. Over the full sweep of the clutch pedal there is approximately 35mm of piston travel @ the master cylinder push rod. Over this 35mm distance there is only approximately 2.5mm deviation of the clevis pin from the centreline (see pic #3). Due to this relatively long stroke of the clutch master (compared to the brake masters) and the frquency of use it's important to minimise this deviation as it creates an angular force on the piston which may increase master cylinder wear / deterioration. The same requirement is needed for the verticle cetreline plane.
Hopefully this one will be completed over the next few days - then onto the others

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Paul
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Paul Dunstan
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Re:Bias pedal box - mk2 2012/02/27 13:25:59 (permalink)
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OK, the cable and hydraulic variants on the Mk2 are all but finsihed - just waiting on a trip to the platers
See below.
I have all but finalised my ideas around the Mk1 hydraulic pedal boxand how to approach  the folowing
  1. Fitting the 3 master cylinders on such a narrow pedal box frame.
  2. Fitting the bias assembly without fouling the clutch or accelerator pedals.
  3. Adopting the OEM accelerator lever / cable configuration and not the Grp4 style which requires altering the position of the cable entry into the cabin.
 
More to come.......
 
 
 

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Paul
#38
Paul Dunstan
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Re:Bias pedal box - mk2 2012/03/20 22:01:13 (permalink)
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Hi All
Finally finished the hydraulic clutch variant of my Mk2 pedal box.
Here are some images.
Now onto the Mk1 version
 

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Paul
#39
Phil
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Re:Bias pedal box - mk2 2012/03/20 23:07:29 (permalink)
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Mate, looks sensational!! Well done!!

Boost...The Natural Enemy of Traction!!!
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evobda2
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Re:Bias pedal box - mk2 2012/03/21 13:12:35 (permalink)
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Looks great Paul!
Quick question, I'm mating mine to the rx7/r31 caliper setup..
What size master cylinders would you recommend? (or anyone else if they have an idea?)

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Ev
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Paul Dunstan
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Re:Bias pedal box - mk2 2012/03/21 18:01:35 (permalink)
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Hi Evan
I'm going 0.625 F & R.

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Paul
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evobda2
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Re:Bias pedal box - mk2 2012/03/21 19:51:08 (permalink)
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I was originally going to go with a 0.7 or 0.75 on the rear.. any reason for the 0.625?
#43
Paul Dunstan
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Re:Bias pedal box - mk2 2012/03/21 21:44:21 (permalink)
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Hi Evan
I just want to be sure that I have the feel in the pedal as in my calculations the 0.700 on the front will be too big in relation to the RX7 callipers (36mm bores). This will lead to a heavy dead pedal.
With this combination front / rear the correct bias is about right using the same size MC front and rear no matter waht size you choose. However the bigger the MC the heavier the pedal for a given required braking effort.
Make sense?

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Paul
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evobda2
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Re:Bias pedal box - mk2 2012/03/21 21:51:48 (permalink)
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I see.. ok i might go with that as well. Sounds good!
 
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