Editing Pedal Box Refurbishment (section)

=====If You’re modding the throttle pedal arrangement (Skip to section 1.3.2.2 if not)=====


*Pedal box closure plate
**Because there is no sensible way to trial fit and adjust the fit of the throttle pedal on the car, I used a scrap piece of aluminium plate to make up a closure plate so I could try it all out off the car.  Any rigid material will do – even thin plywood.  Must be rigid though
**With the pedal box on its end, use a piece of thin card or paper to create a template for the three bolt holes in the end of the pedal box.
**Transfer these hole positions to the material you are using for the closure plate
**Drill 3 x 10mm holes in the plate
**Bolt the plate to the throttle pedal end of the pedal box
**Trace around the pedal box extrusion 
**Unbolt the plate and cut to the traced line

[[Image:Pedal_Box_47.JPG|Temporary closure plate in place]]


*Cut down 2 x Pedal pivot bearings to 4.5mm from the inside face of the flange.  The throttle pedal is approximately 10mm wide and you want the bushes to not quite meet in the middle

[[Image:Pedal_Box_50.JPG|Marking out the pivot bearing for cutting]]
[[Image:Pedal_Box_51.JPG|Pencilled in for clarity]]
[[Image:Pedal_Box_53.JPG|Cutting the bearing]]
[[Image:Pedal_Box_52.JPG|Comparison - before and after shortening]]


*Press the cut down pivot bearings into the throttle pedal 

[[Image:Pedal_Box_54.JPG|Fitted to the throttle pedal]]


*Cut down the Thick spacer bearing to approximately 10mm from the outside face of the flange

*Fix the shaft into the pedal box (you only need to put in one of the two screws at this stage)

*Assemble in this order
**Thrust washer, throttle pedal, shims, Thick spacer washer
**Pedal box closure plate

[[Image:Pedal_Box_56.JPG|Assembly in place]]
[[Image:Pedal_Box_58.JPG|Assembly without the temporary closure plate]]

*The number of shims will be dependent on the exact width of the thick spacer bearing.  Use trial and error to get a stack of shims that allows a smooth running fit with a small amount of resistance.  You can check whether the resistance is unacceptable by fitting the throttle pedal return spring and checking that the pedal snaps back to its upper position under light spring tension.  You are trying to use as few shims as possible to eradicate the side-to-side movement in the throttle pedal.

[[Image:Pedal_Box_59.JPG|Shims in place]]

*Take the closure plate off and store the thick spacer bearing, shims, pedal and thrust washer to one side for final assembly later.  Remove the shaft fixing screw and remove the shaft.

*Fitting the pedals
**Taking car to ensure that the shaft is inserted the correct way around, slide it into the pedal box to the brake pedal aperture.
**Fit a thrust washer and shim stack then the bushed pedal, then another shim stack, then the second thrust washer into the aperture so that there is little or no side-to-side movement of the pedal.  You will find it virtually impossible to totally eradicate this movement as space is tight and it takes some finessing to get the shims and thrust washers aligned when inserting the shaft.
**Repeat step 30b for the clutch pedal.
**I used around 0.2mm of shim either side of the pedal for both of mine, as a guideline

*Fully screw the shaft into position, taking care to ensure that the thrust washers are properly seated on the small machined shoulder of each pedal aperture.

*Refit the throttle pedal with a dab of LM grease between each washer, shim and spacer to ensure that they don’t fall off during reassembly.

[[Image:Pedal_Box_60.JPG|Pedal Box reassembled]]
[[Image:Pedal_Box_61.JPG|Overview of pedal assemblies]]
[[Image:Pedal_Box_62.JPG|Brake pedal detail]]
[[Image:Pedal_Box_63.JPG|Clutch pedal detail]]