Made my own aluminum Gas pedal!!

[Elombard]

Check it out.

I need to replace the round head bolts with something tricker ( cap head allens) but it came out great!.

My pedal was flopping around like crazy. I assumed the rubber at the hinge had worn out or something.

Once again its difficult to improve on the factory. The factory pedal is a rubber coated piece of metal with a very nicely designed metal hinge!!! I thought the whole thing was a hunk of plastic. My hinge had rusted and broken, hence the flopping. If I had known this I would have gone back with a stock pedal (still may do that, I did not drill any holes.

Here is the hinge I used. I drilled it and used the factory location.




Here is the finished product. I cut the stock pedal down and screwed it to the back of the aluminum (the two bolts in the center of the pedal) so the throttle actuator rod would be able to attach like factory (ball socket).






I am thinking drill some holes and "sculpt" the side nearest the tunnel because it rubs the carpet a little. Maybe some of those stick on rubber dots or grip tape to pretty it up!!

It works perfectly and Heel/toe is a breeze because it is so wide.

Best part it cost nothing and only took 30 minutes!! ( I know...it looks like it is worth every penny of free :-)) All function no form.

[masraum]

Grip tape. Looks great. And it's not just a pad that gets applied, it's actually a pedal with it's own hinge. It's always seemed to me that you should either leave the stock pedal or replace the whole thing, not just bolt something on top of the pedal.

Excellent job.

[Tim Hancock]

Ed, nice choice of hinge stock (extruded aluminum aircraft grade)!

[Cdnone1]

I'd be careul, that sure looks like it could be very slipper if your shoes are wet. Youmight want to drill some holes in it to rough up the surface.
Just my 2cents
Steve

[Tim Hancock]

I say leave it slippery, I think you want your foot to easily slide around on the throttle (after all your whole foot basically is "mashing" on it). The brake and clutch pedals need "grip". Of course I am no pro on pedal design!

[Elombard]

I always thought that slippery thing was an issue too. But on a gas pedal its kind of good. When I roll my foot for heel and toe its good if it slides...now on the brake that would be bad.

yah I hope nobody asks me where to get the hinge because I dont know where you get them.

[Tim Hancock]

Not that it matters, but the extruded aluminum hinge stock costs 5-10 times what the same size alum "rolled" hinge costs. The extruded stuff is actually used on many aircraft to mount pivoting control surfaces.

It can be purchased from most aircraft supply houses. No big deal on a simple 2-3" long throttle hinge, I just had to make a comment though.

[Elombard]

Just for grins, I could not find a suitable hinge at a hardware store, where would you find a good selection of rolled hinges? Any ideas?

[derkpitt]

Hey Herman (Munster) nice pedal.
Drill some holes in it will ya.

[Tim Hancock]

I think Home Depot and Lowes type stores will have steel continuous rolled hinge stock.

[Jgordon]

We need weights - stock vs. current, and current vs. drilled/sculpted.

Nice work.

[Wil Ferch]

I've often commented on the need for grip on the clutch and brake pedals..but slippery is good for the gas pedal.

I made a pedal like the one shown here , but in a reverse "L" shape.

Suggestion...chamfer the holes and use flat-top screws so they end up flush with the surface. I did that and it ends up working and looking nice.

Very much like a 935....solid slippery surface and all !!

Wil

[masraum]

You may want to drill some holes and then add a flange which should strengthen and lighten.

http://users.lmi.net/~ryoung/Sonerai/Belling_or_Flanging_Dies.html