Direct action brake servo/master cylinder work with PICS!
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#898481
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Direct action brake servo/master cylinder work with PICS!
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
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Im going to take some pics of the footwell work this weekend and post them up for all to see
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I have a corrado pedal box and 16V servo to use as i need to convert to hydraulic clutch operation also.However i can convert to hydraulic clutch without installing pedal box but not sure if i can install the servo to work from the original mk1 brake pedal location.
This is'nt mine it's from another forum,he's using vento VR6 donor vehicle
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
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Direct action brake servo/master cylinder progress with pics
Given plenty of thought on strength and durability i decided to use the pedal box from a corrado (as it has the hydraulic clutch built into it which i need as i am using an O2A gearbox with my G60 conversion) and weld it directly to the mk1 steering column like the original brake and clutch pedals were.This will make it stronger and safer,i plan to install a strengthening plate into the bulhead and brace this to the lower chassis beneath the servo.
I have taken many pics along the way but here are just a few fo the progress i have made so far.
Before any cutting,just removed original brake system
BIG hole cutout and chassis section removed and inner wing modified(beat in)
Mounting/strengthening panel made from 5mm steel
And welded in place(inside and out)after lots of trial fitting of servo and pedal box
Servo in place and column fits although pedal box not behind servo in this photo
Lots of fabrication left to do and clutch hydraulic's to fitup.
Next job is to make the column fit through the corrado pedal box.
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
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First job was to remove the original pedals from the column
Then make an extra mounting bracket
And make the column fit between the pedals and weld it all up!
And then make sure it fits ok!
Still have much to do but its coming together nicely,need to sort gas pedal and cable and clutch hydraulics then fabricate some closing panels for either side of the mounting/strengthening plate and weld them in.
Will update with more pics when next progress is made this weekend!
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
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As you can see there is quite a bit of room down there maybe even enough room for a turbocharger
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
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Anyway i pulled the motor out and re-enforced the clutch cylinder mount then closed of around it with 20's gauge steel
Then closed of the raintray and the rest of the bulkhead and re-enforced the brake servo mount.
A good clean-up with the grinder
and another trial fit
http://i11.photobucket.com/albums/a168/rustmuncher/15022009865.jpg
Just need to finish of the chassis leg now and re-enforce it a little and its done!
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
Old Timer
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260 views so far and only 2 replies and all that banter on golfgods thread about direct action servo mod.
Come on guys lets have your comments please!!!
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
Old Timer
Keep the pics and up dates coming too !!
G60
Posted
Local Hero
Posted
Old Timer
Mk1 Golf 16V Conversion FAQ Zip, now located at in the Forum WIKI section: http://vwgolfmk1.org.uk/index.php?page=cedi&type=misc&id=42%2F26%2F3
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Re-worked the chassis leg and extened it back to the firewall and strenghtening brace.
Then decided to add a further brace between the two main chassis sections just for good measure and peace of mind!
Thanks to all who have commented and who are watching this thread.
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
Old Timer
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Will probably start a new thread in projects to cover the rest of the engine bay work just so its in the right place and leave this thread to the brake mod,maybe post some pics up after the paint and fit up of the pipes and cylinders etc..etc..
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
Old Timer
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ERROR: A link was posted here (img) but it appears to be a broken link.
currently breaking mk1 caddy,mk2 16v,mk1 cabby pm for prices!
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Old Timer
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Cero said
Very good job sir, really impressed with what you've achieved. What did you need to do to make the Mk1 steering column fit to the Corrado pedal box?
With the column i had to remove the original pedal setup and make an extra fixing bracket
It was the rado pedal box that needed more work to enable the column to fit through it,there isnt much room for error as the clutch hydraulic system and the throttle arm/rod come very close to the universal joints at the bottom of the column where it goes through the bulkhead.Basically i had to split the box in two and reconstruct it either side of the column,I split it where the clutch and brake systems come together and modified them both to fit either side of the column then welded it back together with the column in place.It was far from easy but im happy with the result!This is the brake pedal side of the pedal box with the column welded in.
I hav'nt taken many pics of the work on the pedal box as i was far to brain engaged in the task for pics!
The pedals in place before i worked out how to fit the Go pedal in place
Thats about it for now with the pedals,i will try and remember to take some more pics the next time its out of the car as i need to paint it before final fitment.
Thanks for looking and your comments guys!
1989 caddy
1981 gti
1993 cabby
1981 gti
1993 cabby
Posted
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Inaris silver series 1. APX 1.8T REVO software, hybrid O2J/O2S 6 speed, peloquin diff, cabrio drives, toyota pas, 7.5x16 5X100 compomotive mo flatspokes, G60 ABS, 305 brembos octy vrs rears, coilovers and arb's by H&R
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