Pedal cluster rebuild done!
 

OK, it took a while, but I am happy it's done right, so I am posting this story and pics about the job:

My gas pedal was flopping over and occasionally getting stuck in the full 'on' position (danger danger), so I figured I would tackle one of Wayne's 101 projects. I ordered his bronze bushing kit, and read what I could about the project on this BBS. I pulled the unit out in about 30 minutes. I then cleaned it up with a wire brush, due to 33 years of rust and dirt. I then went to drive out the infamous roll pin (pic #2). OMIGOSH- this part of the project took most of the time. I tired driving it out, no luck, then remembered reading a post about drilling it out using increased size drill bits, which I began to do until I got to about the third larger size and broke not one, but 3 bits, then tried going up to the the bit of the size of the pin itself. No luck either, finally I used plenty of adrenaline and was indeed able to drive it out. I credit the first few successful drill outs to this, it gave the pin room to work with I guess.
Then I was able to take it all apart, clean every piece real well and sand each down, then paint each as well. I then slipped in the new bushings, with a small amount of bearing grease, and put it all back together. The next day installed it and everything went very well.
I am glad to have done it, as I am slowly going through dozens of these types of projects on this car, and realizing how well my 911 is engineered. One day I might drive it too again, I am doing the front sheet metal now, and that is taking a long time.
http://forums.pelicanparts.com/uploa...er_Before2.JPG http://forums.pelicanparts.com/uploa..._Roll_pin3.JPG http://forums.pelicanparts.com/uploa...ter_After1.JPG

The roll pin is a toughy. No to mention the yogo type positions required to do the job. WFIW, after I rebuilt mine I had some sqeeking at the clutch peddle. A little dab of white lit. grease does the trick.

Yeah, I crawled in there pretty far to do it! No squeeks so far, but it is not driving yet either. I did try the pedals a few times to be sure everything was good.

I recently took out my pedal cluster to clean up footwell area and clean up any small rust flakes. Pedal cluster was in ok condition and could probably use a rebuild next year, but it's ok for now.

You are going to paint your pedal cluster with a little POR15 aren't you? I wouldn't want the bare metal to rust.

BTW, is there supposed to be anything where the clutch pedal contacts the floor pan? My clutch pedal goes down to floor pan. I thought there might be some kind of pad to cushion the pedal from the floor.

On the sheetmetal under where it mounts, there was rust, so I cleaned it all real well with a wire brush, then used sandpaper to expose the metal. I then took a liberal amount of Naval Jelly to eat away the rust, let it sit long enough to work, cleaned it out, then sprayed a rustproof primer black onto it before mounting the cluster back in. This took around 3 hours in addition to the cluster rebuild job.
On my assembly, as far as the clutch pedal goes, there is a large expanse of metal close to the pivit point (this could be seen in the 'after' photo) that will hit the base of the cluster before hitting the floor...