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I cut out my bulkhead scuttle closure panel last night, and was quite pleased with the result. There is however a slight warp in the bulkhead towards the centre-has anyone else found this?I believe one builder put in a brace bar.
I cut out my bulkhead scuttle closure panel last night, and was quite pleased with the result. There is however a slight warp in the bulkhead towards the centre-has anyone else found this?I believe one builder put in a brace bar.
That was me. The brace bar also helps to stiffen up the pedal box and provide a landing for the scuttle closing plate. I got mine wrong to start up with and ended up with some spare holes (oops). I'll post up a picture later - there isn't one on my web site that I can find.
Thanks, I think I may use a brace bar, as I have found some flexing to the pedal box, and despite having completed the box months ago, I am not happy with the pedal positioning and brake pedal travel-I havent put in the extra 10mm extension into the servo yet--did someone machine those or is my memory going.....
Thanks, I think I may use a brace bar, as I have found some flexing to the pedal box, and despite having completed the box months ago, I am not happy with the pedal positioning and brake pedal travel-I havent put in the extra 10mm extension into the servo yet--did someone machine those or is my memory going.....
I'm currently having loads of problems with my clutch and the pedal box flexing.
I recommend you double up the metal on both side of the pedal box, add a brace between the two side and beef up the clutch mounting. The accelerator pedal moves about as well so that could do with triangulation.
I had my brake pedal bent to a better position:
I need to take the pedal box out at some point and lots of extra metal and triangulation (wish I'd know before as its a pain in the bum to get in a out).
Thanks Patrick,I shall do this now b4 going any furthur.....it seems I am unbolting more than I am adding presently..suspension, servo, pedal box...but at least all will be properly sorted very soon
I lost count of the number of time I unbolted things The brake pedal change was mainly for my big feet as I could not use the accelerator and brake separately they were so close. I also didn't use the rubber pads, instead I used some sticky back abrasive stuff (like sand paper) from CBS.
In fact there are two issues with the pedal box as it "leaves the factory". (IMHO of course)
1. The bulkhead top to which the pedal box is bolted flexes visibily with the force of using the pedals. I think this is the worse problem and solved or at least improved using a brace as I did.
2. Although the pedal box looks quite robust it also flexes - compounding the above problem. If you brace the bulkhead the brake operation seems much better but the clutch pedal operation still leaves something to be desired.
I assume the problem can't be so great that something eventually breaks as Marlin has been using this arrangement for sometime. But it is a bit disconcerting to watch the clutch master cylinder move each time you use the clutch!
I was not too impressed with the pedal box, so made some changes to strengthen it. Having the clutch pedal, master cylinder and accelerator mounted off single pivot points was never a good engineering solution.
Having just read Patrick/Robin's comments, I wonder if my changes are still not sufficient.
How much does the bulk flex under heavy braking, Patrick?
I was not too impressed with the pedal box, so made some changes to strengthen it. Having the clutch pedal, master cylinder and accelerator mounted off single pivot points was never a good engineering solution.
Having just read Patrick/Robin's comments, I wonder if my changes are still not sufficient.
How much does the bulk flex under heavy braking, Patrick?
- shows the changes I have made so far to at least double end pivot/support the pedals/ master cylinder.
Mike
I've not checked it closely under heavy braking, its more stable as the pedal mounts into both sides, the clutch on the other hand makes the box flex even if I use my hand to push down on it. I've got some 2.5" stainless exhaust pipe bolted between the two sides as a temporary solution. An improvement but not perfect.
One thing I did do on my pedal box is install the bearings from the original E30 pedal box which gives a very smooth movement, some photos at the bottom of this page (and the next): http://www.msportster.co.uk/detail.asp?cat=7&offset=12
How much does the bulk flex under heavy braking, Patrick?
Mike
I didn't measure it but lets just say it was easily visible. When you look at the bulkhead top it is basically just a large flat plate with not a lot of support in the pedal box area. Putting a square tube side to side meant there was no visible movement when standing on the brakes. I bolted the tube right through the pedal box flanges and at regular intervals through the bulkhead top. I took it all the way from side to side where the ends get support from the join to the footwell sides.
I haven't done anything to the clutch pedal mechanism - although I am beginning to wonder if I should. I think that will have to wait post SVA now.
I cut out my bulkhead scuttle closure panel last night, and was quite pleased with the result. There is however a slight warp in the bulkhead towards the centre-has anyone else found this?I believe one builder put in a brace bar.
Hi Jeremy,
there is a warp in my bulkhead as well. I think its the way the chassis is welded together creates the bow. The gap gives a nice flow of wam air from the engine without turning on the heater (:smile but i will probably just seal it with some flexible sealant or foam rubber after everything has been painted.
I have not added any stengthening or mods to my pedal box.
I lost count of the number of time I unbolted things 
The brake pedal change was mainly for my big feet as I could not use the accelerator and brake separately they were so close. I also didn't use the rubber pads, instead I used some sticky back abrasive stuff (like sand paper) from CBS.