Direct action brake servo/master cylinder work with PICS!

Hey has anyone got a link or tips on this? I have been watching the latest thread by golfgod but only for amusement! He is not giving anything away either! I think its selfish that people come to enthusiasts forums and want to tease and make a packet from genuine members or are just full of bullshat!  So come on genuine members can you offer any help?

Hi mate, ive done this to my Mk1 (its in the project section- 'Mk1 2.0 16v on bike carbs')
Im going to take some pics of the footwell work this weekend and post them up for all to see  

Hi mate i have studied the two photo's of the servo mod on your thread very closely and am eagerly awaiting more pics and info.I have found another mk1 with servo mod on another forum,im just trying to gather as much info as i can before cutting my firewall up!
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

Ok after searching and gathering as much information as possible i decided to jump in and hack up my firewall/bulkhead and make it work!
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.

This is the work i needed to do on the column and pedal box to get them together.
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!

Did a bit more this weekend firstly made a panel for the clutch cylinder so i could mount it and then try the engine in the bay to make sure it fits because i was a bit worried it wouldnt.Big sigh of relief when it went in no problem!



As you can see there is quite a bit of room down there maybe even enough room for a turbocharger  

Well no turbo just yet maybe a 2.0 16V G60 next winter but for the time being im sticking with the 1.8 8V G60.
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!

Very nice work! Makes me proper jelous, wish I had the skill, time & tools to do a decent job of mine. It would be cool to drive somebody elses motor with this conversion to feel the difference. Top work, keep the updates coming!

Thanks bouchay at least someone has replied,looks like im a thread killer on this forum too!
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!!!

Certainly making good progress, would it be easier to use a set up from a l/h drive golf ?? Then again i suppose you couldnt have a hydraulic clutch could you ??

Keep the pics and up dates coming too !!

Very impressed .   Keep them pics coming .

Cheers ………..

Good work  8)

Ok done a bit more today and finally the welding is complete,just needs some cosmetics now to smarten it up a bit and then prepare it for paint.
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.

Can'twait to see it all painted up, are you going to tidy the engine up as well? It would make the engine bay amazing if everything looked brand new. Would LOVE to drive it when it's done, just to feel the difference.

Yea im tidy'n the bay up and getting rid of all the uneeded holes and brackets etc.. etc..Not going for a full on smoothed bay and im retaining the firewall upper section,i think you could call it the Tidy'd up OE look! Engine is all painted and polished ready to drop in,still have a lot to do though and parts to find like topfill rad and twin pass intercooler and hoses/pipes and so on!
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..

Well make sure you post a link to the new thread, cos i'm loving it so far :mrgreen:

good work mate

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?

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!

nice work, well done