Jet Jockey/A4 Pilot

Well this turned out to be more problematic then we thought. Because the master cylinders are installed aft of the pedals it increases the total length of the unit by ~ 3.25 inches we quickly realised that if we installed the new pedal set as far back as we could on the original OEM floor, the pedals would be too close to the driver. This would be unacceptable to the driver's leg angles (knees really bent).

The solution was to make a new floor which we had to do anyway because the OEM floor is not strait but undulates with up to 2 inches in depth differences in some spot. To get what I would say is an acceptable leg position for me as the main driver we raised the floor by 4 to 6 inches depending on where you measured from the OEM floor.

So here we go...


You can see that attaching the master cylinders to the pedal set add about 3.25 inches in length overall. We also need room back there to add the fittings for the hard lines for both the front and rear brakes and for the stainless steel line for the clutch.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-2.jpg">


To make the new floor we used a 6061 aluminium plate a ¼ inch thick and we cut it to the shape required for it to fit in place.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-10.jpg">


To secure the aluminium plate in place we welded a right angle of steel to the tranny tunnel.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-11.jpg">


We did the same thing on the left side approximately where the OEM dead pedal used to be located.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-12.jpg">


Now to make sure the new floor wasn't going to flex and move under heavy braking activity we braced the end closest to the driver with another right angle piece of steel that is welded to the rocker panel side and the tranny tunnel side. We also used a square tubing in the middle welded to the floor to avoid any vertical movement.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-13.jpg">


Everything was checked to be level and properly fitting before the final assembly.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-14.jpg">


Once the fitting was successful and the aluminium plate removed the whole assembly was cleaned and primed.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-15.jpg">


Once the primer had dried, several coats of red paint were added.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Brakes-Completere-work-STaSI-16.jpg">


Here's what the semi finished product looks like with the pedals in place.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CompletebrakemodJune2008031.jpg">

Reggie

Great work - I'm sure mance would be proud

Mirror|rorriM

Why not just move your seat back instead?

MikekiM@PureMS

Steering wheel probably becomes out of reach then.

Snow Trooper

Correct, he is using the stock assembly.

Jet Jockey/A4 Pilot

The seat back several inches but not that much because of the roll cage.

If we do end up moving the seat back I would nee to lengthen the steering wheel rod and get a quick release type steering wheel.