Clutch cable end bottoms out before the pedal does

[dmoran]

I'm installing the Wilwood pedal box in a new Mk4 kit and hit the old pedal vs 3/4" member issue. There is plenty (too much) written about it so we don't need to beat that dead horse here. I ran into another related issue that I couldn't find a thread on. The clutch cable end on the quadrant side looks like a stove pipe hat and the top part of the hat hits the bracket bottoming out the clutch at about the same point that the pedal it hits the 3/4 tube:
53288
I did the pedal mod but with this cable situation I still don't have much pedal travel.

I put the quadrant together backwards and now the cable end hits the hole perfectly:
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But now, the cable doesn't line up very well:
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When pushing the clutch, the cable rubs along quadrant edge which I'm sure will wear down the cable. Is this a known/common issue or did I put something together wrong?

I could elongate that hole but I really hate to keep cutting into perfectly good stuff. It took two days of forum posts to convince myself the only decent options were; cut the frame or cut the pedal.

Thanks,
Doug

[wallace18]

I had to open up that hole for my cable with a die grinder. No big deal. see post #35.

http://thefactoryfiveforum.com/showthread.php?19828-Wallace18-quot-s-MK4-Build-Thread

[CraigS]

Pull the cable assembly out of the firewall, find a deep socket (or a piece of pipe) that fits in the tube in the firewall, add a long extension, push/pull the extension side ways to align the firewall tube so it aims at the pedal better.

[dmoran]

I ended up cutting a notch:

53833

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Final assembly and paint:

53834

[Mark Dougherty]

yep
same here I always clearance with a die grinder

[Mesa Mike]

looks like a good and easy fix