Ok, so I was playing hookie from work and I got bored. I had an idea...I was looking at the brake/rudder pedal assemblies and I saw those little round circles on the end of the 7/8" tubing. What apain, I thought, to make those. So, I got to looking at the holesaw and arbor I got from Home Depot. I think Sandvic makes them...but anyway...
The drill bit in the arbor is 1/4", too big for the brake pivot shaftdiameter of 3/16". So, I dug through my scrap steel box and pulled out some 5/16" solid steel bar...some cheap stuff I think I picked up at Tractor Supply awhile back. I chucked it in the lathe and drilled the centerout 11/64". I turned the outside down to .250.
I then cut off the piece at .750 length and inserted the drill shank into the adapter I just made. I filed a groove for the arbor set screw like so:
Insert into holesaw arbor and procede to cut 8 circles with perfectly centered holes out of .100 4130 sheet. Your 11/64 hole is then ready to be reamed out to 3/16" for the pivot axles.
Make sure you put the sheet on top of some wood. I used 300rpm setting on my drill press and kept lots of lube/coolant on the holesaw. It did all eight without damaging any teeth.
You'll have to dress the edges with your belt sander or file.
Then I got to the task of cutting the rest of the pieces I'll need for the pedals.
The rectangle pieces will form a circular shape around the 7/8" tube at the top of the rudder pedal, where it is welded to the verticle 7/8" tube that holds the brake pedal shaft.
I'll round it off once I get sone 7/8" tubing to match it up with.
Next was the brake master cylinder brackets. Cut to shape/length and welded around the perimieter to 3/4" from the end. I clamped the drilled end together with a bolt, and clamped the other end to some 1/2" steel bar fromt he scrap box. Finished product waiting to be welded on to the brake pedal:
I cut some1/2" .035 tubing I had laying around. I tack-weldedtwo corners. the bottom piece I left loose because I have to notch the center piece. More to come later....here is what I fitted up:
Enough for now....I'm tired. I have to order me some 7/8" tubing and get some sleep.
The drill bit in the arbor is 1/4", too big for the brake pivot shaftdiameter of 3/16". So, I dug through my scrap steel box and pulled out some 5/16" solid steel bar...some cheap stuff I think I picked up at Tractor Supply awhile back. I chucked it in the lathe and drilled the centerout 11/64". I turned the outside down to .250.
![20071008_180354_holesaw1.jpg](https://proxy.imagearchive.com/447/447e0d92fca8e197a2af25c67b093942.jpg)
I then cut off the piece at .750 length and inserted the drill shank into the adapter I just made. I filed a groove for the arbor set screw like so:
![20071008_180534_holesaw2.jpg](https://proxy.imagearchive.com/60c/60cbd006a2639421964ebbdf7cbc3106.jpg)
Insert into holesaw arbor and procede to cut 8 circles with perfectly centered holes out of .100 4130 sheet. Your 11/64 hole is then ready to be reamed out to 3/16" for the pivot axles.
Make sure you put the sheet on top of some wood. I used 300rpm setting on my drill press and kept lots of lube/coolant on the holesaw. It did all eight without damaging any teeth.
![20071008_180842_holesaw3.jpg](https://proxy.imagearchive.com/1f5/1f5be65db618df95d477df61f4bb68ac.jpg)
![20071008_180939_holesaw4.jpg](https://proxy.imagearchive.com/ffb/ffbd1c00cfef36f5fc3fddd4ea5a5b85.jpg)
You'll have to dress the edges with your belt sander or file.
Then I got to the task of cutting the rest of the pieces I'll need for the pedals.
![20071008_181107_pedal2.jpg](https://proxy.imagearchive.com/511/5116ddad60fee1e5f9d19809e8195501.jpg)
The rectangle pieces will form a circular shape around the 7/8" tube at the top of the rudder pedal, where it is welded to the verticle 7/8" tube that holds the brake pedal shaft.
I'll round it off once I get sone 7/8" tubing to match it up with.
Next was the brake master cylinder brackets. Cut to shape/length and welded around the perimieter to 3/4" from the end. I clamped the drilled end together with a bolt, and clamped the other end to some 1/2" steel bar fromt he scrap box. Finished product waiting to be welded on to the brake pedal:
![20071008_181716_pedal3.jpg](https://proxy.imagearchive.com/c46/c469c43adb29670f47f536f63526dc3c.jpg)
I cut some1/2" .035 tubing I had laying around. I tack-weldedtwo corners. the bottom piece I left loose because I have to notch the center piece. More to come later....here is what I fitted up:
![20071008_181459_pedal1.jpg](https://proxy.imagearchive.com/6c0/6c0aafeacd7b113217e5555eb14e37b0.jpg)
Enough for now....I'm tired. I have to order me some 7/8" tubing and get some sleep.