boat737
03-22-2016, 12:14 AM
To start, this is my first ever post. Be gentle with me. Second, I know many threads have had many ideas and fix's for the frame/clutch pedal interference problem, and I haven't seen them all, so I hope I'm not posting an idea that someone already has posted. If so, then disregard what follows.
I got my MK4 project in a partially completed state. The previous owner had cut out a wedge shaped notch in the 3/4" tube to make room for the Wilwood clutch pedal arm. My idea (and it was mine, apologies to any that came up with the same plan before me) was to put a 1/4" X ~9/16" X ~4.5" INSIDE the 3/4 square tube. That way, there would be no bulky additional 3/4" tube sticking out on the side. The wedge hole that was cut in my tube is about 1.5 inches long, and with the corners and ends of my reinforcing piece of steel ground down just a bit, it slides right inside the tube.
I drilled three holes in the reinforcement steel in order to tap the holes out to a 1/4-20 thread. Before tapping that piece, I used it as a template to drill the same three holes into the 3/4 frame tube, on the outside (left face) of the frame tube. Then drilled those holes out to 1/4 inch. I tapped the reinforcement strap. For good measure, and to add a bit more permanency to the strap, I mixed up some J-B Weld and loaded up the reinforcement strap with it. Once the strap was inserted into the 3/4 tube, three 1/4-20 stainless bolts were inserted to tighten it from the inside.
I realize that that 3/4" tube probably doesn't provide any real structural integrity, but it just didn't seem right to leave that gaping hole in it untouched. The whole thing probably took about an hour and a half, mainly because I needed to rip that 1/4" steel into a 9/16" (or so) wide strap. Mostly, it went smooth and easy.
Looking down through the pedal box to the cut into the 3/4" tube.
51858
I used the steel reinforcement strap as a template to drill the 3 holes in the 3/4" tube.
51859
The reinforcement strap after the three holes were tapped to 1/4-20 thread.
51860
Looking down, you can just see the reinforcement sitting inside the 3/4" tube.
51861
Finished project. Only the three hex bolts visible. I would have used allen head button head screws, but didn't have the right size handy, and didn't want to go to the store for 3 measly screws.
51862
I got my MK4 project in a partially completed state. The previous owner had cut out a wedge shaped notch in the 3/4" tube to make room for the Wilwood clutch pedal arm. My idea (and it was mine, apologies to any that came up with the same plan before me) was to put a 1/4" X ~9/16" X ~4.5" INSIDE the 3/4 square tube. That way, there would be no bulky additional 3/4" tube sticking out on the side. The wedge hole that was cut in my tube is about 1.5 inches long, and with the corners and ends of my reinforcing piece of steel ground down just a bit, it slides right inside the tube.
I drilled three holes in the reinforcement steel in order to tap the holes out to a 1/4-20 thread. Before tapping that piece, I used it as a template to drill the same three holes into the 3/4 frame tube, on the outside (left face) of the frame tube. Then drilled those holes out to 1/4 inch. I tapped the reinforcement strap. For good measure, and to add a bit more permanency to the strap, I mixed up some J-B Weld and loaded up the reinforcement strap with it. Once the strap was inserted into the 3/4 tube, three 1/4-20 stainless bolts were inserted to tighten it from the inside.
I realize that that 3/4" tube probably doesn't provide any real structural integrity, but it just didn't seem right to leave that gaping hole in it untouched. The whole thing probably took about an hour and a half, mainly because I needed to rip that 1/4" steel into a 9/16" (or so) wide strap. Mostly, it went smooth and easy.
Looking down through the pedal box to the cut into the 3/4" tube.
51858
I used the steel reinforcement strap as a template to drill the 3 holes in the 3/4" tube.
51859
The reinforcement strap after the three holes were tapped to 1/4-20 thread.
51860
Looking down, you can just see the reinforcement sitting inside the 3/4" tube.
51861
Finished project. Only the three hex bolts visible. I would have used allen head button head screws, but didn't have the right size handy, and didn't want to go to the store for 3 measly screws.
51862