Rosco's haynes Build

[Rosco]

Then a mk1 gear lever, just as a starting point

[Rosco]

Right no updates for a few weeks, still waiting on laser cutting and to get my exhaust back so I've got a little side project to keep me busy

Ive been after this for about a year as it's been sitting in a blokes yard, he finally sold it me last Saturday afternoon



I borrowed a trailer to get it home on, but it weighs about a ton so we had to strip it to get it up the garden!

The bed took 4 of us to lift and so did the stand



Gearbox was mint



Loads of bits to clean up

[Rosco]

Base and bed ready for paint

[Rosco]

Clean parts bin filling up



Covers and parts ready for paint

[Rosco]

Parts painted by my dad while I've been at work







And that's where it's up to, cheers for looking

[Tatey]

Build is looking very good Ross and lathe is a stunner now it's painted!

How are you planning on stopping the pedals from falling forwards? I only ask as I have now got to the stage where I am finishing my pedal box, I've found the polymer bushing with 8mm bolt through it to be a poor pedal pivot solution when used with the bent brackets to stop the pedals falling forward.

You need to the pedal pivot bolt loose otherwise you end up clamping the pedal to the pedal box but the bent brackets need the pivot bolts tight to provide enough clamp load to prevent them from rotating.

To solve this I'm going to make some crush tubes (1/2" OD) to fit inside the bushes (drilled out to slightly larger than crush tubes OD) which are slightly longer than the bushes (about 0.5mm either side), meaning the pedals will rotate about the crush tubes instead of the bolt. This is the same method used for the suspension bushes but I'll have a bit more clearance between the crush tube OD and the ID of the pedal bushes so that its a smooth pedal movement.

I'll let you know this weekend if it works as expected .

[Rosco]

Originally Posted by Tatey

Build is looking very good Ross and lathe is a stunner now it's painted!

How are you planning on stopping the pedals from falling forwards? I only ask as I have now got to the stage where I am finishing my pedal box, I've found the polymer bushing with 8mm bolt through it to be a poor pedal pivot solution when used with the bent brackets to stop the pedals falling forward.

You need to the pedal pivot bolt loose otherwise you end up clamping the pedal to the pedal box but the bent brackets need the pivot bolts tight to provide enough clamp load to prevent them from rotating.

To solve this I'm going to make some crush tubes (1/2" OD) to fit inside the bushes (drilled out to slightly larger than crush tubes OD) which are slightly longer than the bushes (about 0.5mm either side), meaning the pedals will rotate about the crush tubes instead of the bolt. This is the same method used for the suspension bushes but I'll have a bit more clearance between the crush tube OD and the ID of the pedal bushes so that its a smooth pedal movement.

I'll let you know this weekend if it works as expected .

Cheers mate, I'm going to look at it when the box is together, maybe alter a pedal side or something, is it a requirement for iva? I get what your saying about the crush tubes but can't you just weld the stop to the side mount? Then bolt though as before?

[Tatey]

I believe it is a requirement, but not 100% sure, however you really will want front pedal stops as the pedals fall forward really easily which could get interesting if you're out driving.

I wouldn't recommend welding the pedal stop to the side mount as you then can't adjust it meaning you might end up with a lot of travel before getting tension on the cables or constantly tension your clutch/throttle.

I've seen others that have welded stops onto the outside of the pedal and used bolts through the floor the same way the brake pedal works.

I made the mods to my pedals and it works a treat.