Editing Pedal Box Refurbishment (section)

===My solution to the problem===


[[Image:Pedal_box_diagram_2.jpg|Improved Throttle Pedal Location]]

In essence, I shortened both bearings that would normally be used so that they would fit the pedal as per the other pedals, then found a suitable larger bush to fit and use as a spacer. Because I would be manually modifying these parts, I needed some method to get a good close running fit, so found some suitable shim washers in varying thicknesses to take up the slack.  I ended up using the same shim washers to take out most of the axial play in the other pedals too.

Net result is that both shoulders of the throttle pedal are properly supported, and there is a much larger bearing area on the pedal/spacer interface.  Should last much longer!

'''The parts list I ended up using is below:'''


[[Image:Pedal_box_Table_2.jpg|Flying Banana's Parts Table]]


I managed to get the thrust washers from [http://www.igus.co.uk igus]  who very usefully have a free sample ordering option.  I chanced my arm and asked for 5 as free samples.  You have to put in some info and rationale – I said that I am designing a modular lightweight automotive pedal box system (not a million miles from the truth) and they showed up the next day!  For those of you with a higher sense of ethics than me, they can be bought from the same source and will cost you a total of £18.35 for 5, which is still cheaper than Lotus.  As far as I can tell, they are exactly the same part.  In fact, the pivot bearings seem to be exactly the same as igus part number JFM-2023-11.  These are cheaper from Lotus though.


The thick spacer bearing and shim washers came from [http://www.ondrives.com ondrives].  These parts took a little longer to arrive, around two weeks.  Plan accordingly if you’re not blagging shims from me :)

In fairness, I did also buy two additional bags of shims – 0.5mm and 1mm thick because I had no idea how much clearance I’d need to take up.  I didn’t use any of them so you’ll most likely only need the 0.1mm and 0.2mm shims.

Of course, I now have a bag of 94 0.1mm shims and a bag of 98 0.2mm shims, so if anyone is interested I can send you a few  - just u2u me :)