Mad idea - aluminum pedal set on the cheap?
08-27-2002, 04:33 AM
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Mad idea - aluminum pedal set on the cheap?
Now that I've fixed the driver's side door sensor and lock and got my battery charged, I think I need another project :¬)
I like the look of those aftermarket aluminum 'heel-and-toe' style pedals, a la Rennline, Wings, etc. However, I'm also a cheapskate, and I figure that $200 or so is a lot of $$$ for some small bits of alu (I'm feeling a bit poor at the moment), and I reckon I can make some myself for... well, I think $20 ought to do it. I've got a few questions, though:
- has anyone else tried this? (or, to put it another way, am I mad to try?)
- what kind of sheet thickness do the expensive ones use? I'm thinking of 4mm or 5mm (3/16s of an inch) alu sheet. Any ideas?
- what to use for grip? I'm thinking either raised metal (this is what I'm planning at the moment), or rubber strips (glued into grooves routed across the pedals).
If anyone is interested, I'll be happy to document/take pictures as I go along...
I like the look of those aftermarket aluminum 'heel-and-toe' style pedals, a la Rennline, Wings, etc. However, I'm also a cheapskate, and I figure that $200 or so is a lot of $$$ for some small bits of alu (I'm feeling a bit poor at the moment), and I reckon I can make some myself for... well, I think $20 ought to do it. I've got a few questions, though:
- has anyone else tried this? (or, to put it another way, am I mad to try?)
- what kind of sheet thickness do the expensive ones use? I'm thinking of 4mm or 5mm (3/16s of an inch) alu sheet. Any ideas?
- what to use for grip? I'm thinking either raised metal (this is what I'm planning at the moment), or rubber strips (glued into grooves routed across the pedals).
If anyone is interested, I'll be happy to document/take pictures as I go along...
08-27-2002, 12:43 PM
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<strong>I like the look of those aftermarket aluminum 'heel-and-toe' style pedals, a la Rennline, Wings, etc. However, I'm also a cheapskate, and I figure that $200 or so is a lot of $$$ for some small bits of alu (I'm feeling a bit poor at the moment), and I reckon I can make some myself for... well, I think $20 ought to do it. I've got a few questions, though:
</strong>
I probably have even less money (read: am a bigger cheapskate). I just screwed a piece of wood to the accelerator pedal. Works perfectly
See <a href="http://jwhub.xtdnet.nl/porsche/idx-steering.html" target="_blank">here</a> for measurements of the wooden block.
Cheers,
JW
</strong>
I probably have even less money (read: am a bigger cheapskate). I just screwed a piece of wood to the accelerator pedal. Works perfectly
See <a href="http://jwhub.xtdnet.nl/porsche/idx-steering.html" target="_blank">here</a> for measurements of the wooden block.
Cheers,
JW
08-27-2002, 01:22 PM
#3
Three Wheelin'
Somebody in our club did that to his Boxster and the alum he used even had the Porsche emblem on it. I can't remember where he got it, and I don't even remember who it was.(It's awful to be old.) I will ask around and find out the info, and post it on this entry.
Bill Seifert
91 C2 Cab
Bill Seifert
91 C2 Cab
08-27-2002, 02:42 PM
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Eion
Having stumped up the cash for the Rennline pedals and foot rest I cannot see that I bought anything that a half-competent metal worker could not produce given the right metal and cutting/drilling tools. The ones I have are just shaped plates that are attached by screws drilled straight into the existing pedals.
Good Luck - hey maybe you could discover a profitable side line <img src="graemlins/xyxwave.gif" border="0" alt="[bigbye]" />
Having stumped up the cash for the Rennline pedals and foot rest I cannot see that I bought anything that a half-competent metal worker could not produce given the right metal and cutting/drilling tools. The ones I have are just shaped plates that are attached by screws drilled straight into the existing pedals.
Good Luck - hey maybe you could discover a profitable side line <img src="graemlins/xyxwave.gif" border="0" alt="[bigbye]" />
08-27-2002, 03:55 PM
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Right, excellent, I think I'll start work soon. I've got a 'pattern' for the brake/clutch pedal covers (easy, by drawing around the existing rubber), but they're not the important one. I'll work out a pattern for the accelerator pedal in a while.
When I'm done, I'll post pics, and I'll make my templates available to anyone who wants them. I think I should be able to do the job with just a Dremel and possibly a punch of some sort - we'll see.
One question for Ruairidh (and other owners of aftermarket pedals) - roughly how thick is the sheeting used? Obviously thinner is cheaper and easier to work with, but it's got to be strong enough so it doesn't bend.
When I'm done, I'll post pics, and I'll make my templates available to anyone who wants them. I think I should be able to do the job with just a Dremel and possibly a punch of some sort - we'll see.
One question for Ruairidh (and other owners of aftermarket pedals) - roughly how thick is the sheeting used? Obviously thinner is cheaper and easier to work with, but it's got to be strong enough so it doesn't bend.
08-27-2002, 05:07 PM
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Eion,
I've made my own gas pedal from 3/16 stock alum. Like you, I don't have the money to buy the expensive set. I only did the gas pedal and left the clutch and brake pedals stock because of grip issue. Oh, I also did the dead pedal as it is normally the most expensive of the 4 pieces.
I used the techart's pedal as the template from catalog. I think I like the new Rennline template more and will try to make another soon.
If you have the template already, please send me one at dtdvo@yahoo.com.
Thanks,
Sonny
ps: You will need some sort of cutter. I found out later on that using a scroll saw was the easiest.
I've made my own gas pedal from 3/16 stock alum. Like you, I don't have the money to buy the expensive set. I only did the gas pedal and left the clutch and brake pedals stock because of grip issue. Oh, I also did the dead pedal as it is normally the most expensive of the 4 pieces.
I used the techart's pedal as the template from catalog. I think I like the new Rennline template more and will try to make another soon.
If you have the template already, please send me one at dtdvo@yahoo.com.
Thanks,
Sonny
ps: You will need some sort of cutter. I found out later on that using a scroll saw was the easiest.
08-27-2002, 08:37 PM
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Right, I've just gone shopping.
I couldn't find any 3/16s aluminum sheet, so I'm using 1/4. Total cost of aluminum - a bit over $25, but I've got a fair bit more than I need, I guess, so I may have some spare.
I think I may leave the brake and clutch pedals for a while, or at least until I can work out how to bend 1/4" sheet (really thick!) to the right shape.
Regarding the dead pedal - what exactly is it for? Sorry for the newbie question...
I don't have the template for the accelerator yet, but I'm working on it - as soon as I've got one that works for me, I'll see if I can work out a way to get it to you (I'm working on pen and paper, not computer, and I don't have a scanner - but I'll work something out).
Tool-wise - I'm using a Dremel with a tungsten carbide cutter, which should do the job nicely, along with the usual grinding stones and some stainless-steel brushes for finishing. I'm still not sure what I'm going to do for grip - I'll cross that bridge when I come to it.
I couldn't find any 3/16s aluminum sheet, so I'm using 1/4. Total cost of aluminum - a bit over $25, but I've got a fair bit more than I need, I guess, so I may have some spare.
I think I may leave the brake and clutch pedals for a while, or at least until I can work out how to bend 1/4" sheet (really thick!) to the right shape.
Regarding the dead pedal - what exactly is it for? Sorry for the newbie question...
I don't have the template for the accelerator yet, but I'm working on it - as soon as I've got one that works for me, I'll see if I can work out a way to get it to you (I'm working on pen and paper, not computer, and I don't have a scanner - but I'll work something out).
Tool-wise - I'm using a Dremel with a tungsten carbide cutter, which should do the job nicely, along with the usual grinding stones and some stainless-steel brushes for finishing. I'm still not sure what I'm going to do for grip - I'll cross that bridge when I come to it.
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08-28-2002, 02:06 AM
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Well, by my reckoning I've got enough of this plate to make 6 heel-and-toe accelerators. The dead pedal (and brake/clutch) is definitely going to need to be thinner plate - there's no way that this 1/4" is going to bend (short of using a huge press). I'm still trying to work out how to do the grip thing, too... hmmmm.
I've got a template drawn out on the sheet metal - I'm going to cut it tomorrow and see how it works (I mocked it up on cardboard and it seems good). Will post more when there's more to say (and I should have photos, too :¬).
I've got a template drawn out on the sheet metal - I'm going to cut it tomorrow and see how it works (I mocked it up on cardboard and it seems good). Will post more when there's more to say (and I should have photos, too :¬).
08-30-2002, 01:43 AM
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Right, I've finished the accelerator, and it looks gorgeous. I've got a couple of pics, but I can't figure out how to post them. Anyone?
Next step is the dead pedal (having seen how the carpet in my car is worn away, I think I've worked out what it's for), which I think I'll do in 1/4", then I'm going to get some 1/8" and do the brake and clutch.
Next step is the dead pedal (having seen how the carpet in my car is worn away, I think I've worked out what it's for), which I think I'll do in 1/4", then I'm going to get some 1/8" and do the brake and clutch.
09-06-2002, 03:20 PM
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Three Wheelin'
I got a catalog yesterday from OMP. They make seats, drivers suits, helmets, steering wheels, etc. They also make alum pedals. Their 1010 series includes a brake, clutch and gas pedal, and costs $44.95. A dead pedal is $49.95. This is for silver, but they come in red blue, yellow,and black. The phone number on the catalog is 1-800-275-4667.
09-06-2002, 06:12 PM
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Hello,I bought a set of aluminum pedals from
UPON 3 Racing. The pedals are well made but
I also thought that I could have taken the
time and made a set of aluminum pedals. The
tricky part would have been bending the brake\
clutch pedals. I have installed the accelerator
pedal and the dead pedal. The stock Porsche
brake\clutch pedals are extremely hard to drill.
I have used several Sears drill bits without
completing one hole. I hope to have these pedals attached the next time I come home.
UPON 3 Racing. The pedals are well made but
I also thought that I could have taken the
time and made a set of aluminum pedals. The
tricky part would have been bending the brake\
clutch pedals. I have installed the accelerator
pedal and the dead pedal. The stock Porsche
brake\clutch pedals are extremely hard to drill.
I have used several Sears drill bits without
completing one hole. I hope to have these pedals attached the next time I come home.
09-06-2002, 06:20 PM
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I have the OMP pedal set (Model 1010 - $44.95 from Driving Impressions) installed on both of my P-cars.
Great foot feel and they look nice too. The installation is easy. The hardest part is finding a hardware store that carries metric nuts and bolts that are long enough to thread thru the pedal.
You will want to disconnect the throttle cable and remove the plastic pedal from the car to complete the installation.When you layout the throttle pedal, pay carefull attention to the web and socket molded into the pedal.
You will want a new sharp drill bit. Remove the original rubber covers from the clutch and brake pedal. The original metal pedals are very hard. Go easy, it will take sometime to drill through.
When I installed them on the cars I made a series of full size wood shims 3/16" X 4" for the gas pedal. I scribed the shims to match the aluminum pedal and painted them black. Can't even see that they are their. This allowed me to very effectively raise the height of the pedals without messing with 'lowering' the brake pedal.
Heel and toe is now effortless. With the roll of the ball of my foot I can blip the throttle while applying plenty of brake pressure.
OMP also sells rubber inserts for the pedals as well if you DOT requires rubber surface on the pedal.
Good Luck.
marc
<img src="graemlins/yltype.gif" border="0" alt="[typing]" />
Great foot feel and they look nice too. The installation is easy. The hardest part is finding a hardware store that carries metric nuts and bolts that are long enough to thread thru the pedal.
You will want to disconnect the throttle cable and remove the plastic pedal from the car to complete the installation.When you layout the throttle pedal, pay carefull attention to the web and socket molded into the pedal.
You will want a new sharp drill bit. Remove the original rubber covers from the clutch and brake pedal. The original metal pedals are very hard. Go easy, it will take sometime to drill through.
When I installed them on the cars I made a series of full size wood shims 3/16" X 4" for the gas pedal. I scribed the shims to match the aluminum pedal and painted them black. Can't even see that they are their. This allowed me to very effectively raise the height of the pedals without messing with 'lowering' the brake pedal.
Heel and toe is now effortless. With the roll of the ball of my foot I can blip the throttle while applying plenty of brake pressure.
OMP also sells rubber inserts for the pedals as well if you DOT requires rubber surface on the pedal.
Good Luck.
marc
<img src="graemlins/yltype.gif" border="0" alt="[typing]" />
09-06-2002, 10:19 PM
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My finished product...
I still haven't got round to getting any thinner metal to do the other pedals - but I will sooner or later. Total cost? Not including all the tools I had to buy that I should have had anyway (like a hacksaw, a drill, a file...), about $5 (I spent $24 on aluminum and got enough to make 6 pedals - the bolts cost me an additional dollar or so).
I still haven't got round to getting any thinner metal to do the other pedals - but I will sooner or later. Total cost? Not including all the tools I had to buy that I should have had anyway (like a hacksaw, a drill, a file...), about $5 (I spent $24 on aluminum and got enough to make 6 pedals - the bolts cost me an additional dollar or so).
