Which pedal set for manual conversion

[ainarssems]

We had a look at D2 and C5 pedal boxes at A8parts open day and they are way different not similar at all. Having had a look at dismantled car we came to conclusion that one of the best ways probably would be to get the LHD pedal set, fit them to the RHD pedal box making a bend in pedals most likely by cutting them and welding a piece of metal in middle to move them more to the right side to fit in footwell.

[RanjS8]

Well I decided to contact Tozo in America today to get some advice on the pedal cluster....and how he fit the hydraulic line and these are the pics he sent.

My plan is to get a rhd pedal cluster and make it into the picture below....then it is a case of making space for the clutch pedal....lets see how it goes....

The pictures by the way are awesome and I m sure will be a great help...

[Goran]

Thanks for the pictures.
The problem with the RHD pedal box is that the opening & mounting point for the brake booster is on the opposite side to the LHD pedal box, right in the way of where the clutch pedal master cylinder should go. I'm not saying its impossible but its going to be a really tight squeeze.
On the positive note, Tozo's custom over-centre spring for the clutch pedal looks like exactly what we need, because there is no way the huge, wide LHD over-centre spring will fit on the RHD pedal box.
Also, the brake pedal spring mounting bracket needs to be cut off and moved to the other side of the brake booster well.
In the picture is a RHD pedal box, with the LHD brake pedal held in place to show where it could potentially be fitted as a clutch pedal. However both the brake pedal and LHD brake pedal bushings would need to be cut down to fit on the remainin space of the pedal shaft.
There is nothing behind the plastic foot rest, plenty of space for the clutch pedal, but no space to rest your foot.
Ideally I would like to keep a smaller version of the foot rest, but that would require bending the gas pedal to the right, reducing the (overly wide) fuse cover, bending the RHD brake pedal to the right and cutting down its rubber mounting plate so the smaller LHD brake pedal rubber pad can be fitted instead, and using a second RHD brake pedal as the clutch. I beleive this could also be possible keeping a small footrest, but with pedal spacings reduced to about 5cm (may be too tight). See last picture for a stiched together picture of the shifted narrowed pedals idea, possibly enough room for small foot rest.

Personally, my plan is to ask Grizz from Unit 20 his opinion how its best to design the pedal box and if he is willing to put it together (I'm no engineer and as IT said I dont want anything to brake, feet can exert a lot of force). I need something else fixing soon so when I get booked in I'll just take all the pedal bits to him and see what he says.

[RanjS8]

The clutch master cylinder will either have to be mounted at an angle or possibly be mounted in the engine compartment with a rod type or spring type mechanism mounted on the clutch pedal to press on it.

I wouldnt worry about the footrest issue at present...just a working pedal cluster is the priority. I truly believe this is possible now...