RX8Club.com
Register Photo Gallery FAQ Members List Calendar Search Today's Posts Mark Forums Read RX8 Live!Used CarsVendor Directory

Go Back   RX8Club.com > Series I Tech & Performance > Series I Do It Yourself Forum
Sign in using an external account
Register Forgot Password?

Welcome to RX8Club.com!
Welcome to RX8Club.com,

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, at no cost, you will have access to start new topics, reply to conversations, privately message other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join RX8Club.com today!


Reply
 
 
 
 
LinkBack Thread Tools Search this Thread Rate Thread Display Modes
Old 10-31-2003, 06:03 PM   #1
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Clutch pedal Extension instructions with Pics

For those of you, like me, who find the driving position in the RX-8 uncomfortable due to the gas pedal being too close, I have worked out a solution.

After much carefully controlled scientific experimentation, (ok, ok, with a small piece of 2x4 lumber and some duct tape!) I was able to determing that if I could extend the clutch pedal about 1.5 inches, I could comfortably depress it with the seat back where I like to have it. This also allowed me to extend my right (accelerator) leg to a much less bent position, which was my main goal. Here's how I did it.

You need the following:

- One piece of approx 3x3 inches 10 gauge sheet metal
-One 5 inch long x 1 3/4 inch x 1 1/2 inch, 3 sided "2x4 reinforcing bracket" (Kind of a squareish U-shaped) (Found in the fencing section of Home Depot or similar hardware store) (See pic 4)
-Two 1 3/4 inch hose clamps
-Eight approx 1/2 inch long, 1/8 inch diameter nuts, and matching bolts
-Eight washers to match the bolts
-A drill with a 1/4 inch bit that will bore metal
-A hack saw
-Black spray paint
-A Sharpie or similar marker, something that will draw on the sheet metal
-About 4 inches of 2 sided foam tape
This ad is not displayed to registered and logged-in members.
Register your free account today and become a member on RX8Club.com!
__________________

Last edited by Omicron; 11-07-2003 at 03:35 PM.
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:04 PM   #2
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 1: Remove the clutch pedal foot piece. It hooks to the pedal itself via a rubber flange that wraps around the edges of the pedal. I was able to flex the rubber flange around the edges and pop it right off.

Step 2: Put the sheet metal square up against the now-uncovered clutch pedal, and trace the outline of the pedal onto the sheet metal.

Step 3: Using a hack saw, follow the outline you just traced, and cut the sheet metal so that it is the same size and shape of the uncovered clutch petal. You have just made a replacement clutch pedal piece that the pedal will eventually snap onto just like it did the original clutch pedal.
NOTE: Be sure you make this backing the same size or slightly smaller than the "naked" clutch pedal, or you'll have a hell of a time getting the pedal to slip onto it.
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext01.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:05 PM   #3
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Another pic
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext02.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:05 PM   #4
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
and another
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext03.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:09 PM   #5
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 4:

Cut the "2x4 reinforcing bracket" down into two, two inch long equal size pieces.Both will be about 1/2 shorter than the sheet metal you just cut in step 3.
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext04.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:09 PM   #6
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 5:

Fit the 2 pieces of the reinforcing bracket together like this:
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext05.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:10 PM   #7
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
another pic
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext06.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:12 PM   #8
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 6:

Drill holes as needed in the sides of the reinforcing bracket pieces so you can bolt them together. I put 2 holes on each side.

Here you see the square, open-ended "box" you just assembled next to the clutch pedal piece. It looks like they are the same size in this pic, but the clutch pedal piece is actually longer and wider by about 1/2 inch.
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext07.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:13 PM   #9
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 7:

Put the clutch pedal piece you've made on top of the "box" and drill 4 holes for mounting it to the box.
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext08.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:15 PM   #10
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 8:

Using 2 washers per hole as stand-offs, mount the clutch pedal piece you've made on top of the "box." Now paint the entire thing black.
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext09.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:16 PM   #11
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 9:

Snap the factory clutch pedal cover over the clutch pedal backing" piece you've made by gently prying the rubber "lip" back and popping it into place. when you're done, it will look like the pic below.
NOTE: If you made the backing piece too big in step 3, you may have to make it smaller before the pedal will fit over it. And this is a PITA to get on, regardless of how close the backing isto the right size. You may want to use some "303" (or similar) spray to give the pedal cover lips a good lubing, then hold the box in a vise and use a couple of small screwdrivers to pull the cover on.
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext10.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:17 PM   #12
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
another pic
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext11.jpg  
__________________

Last edited by Omicron; 10-31-2003 at 06:27 PM.
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:17 PM   #13
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
and another
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext12.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:18 PM   #14
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 10:

Next, partially flatten out the hose clamps, open them, wrap them around the back of the "box" (opposite the pedal) and hook them back together.
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext13.jpg  
__________________

Last edited by Omicron; 10-31-2003 at 06:27 PM.
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:20 PM   #15
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 11:

Now cut the two sided tape into two 2 inch strips and attach it to the actual clutch pedal
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext15.jpg  
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:21 PM   #16
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Step 12:

Finally, put the new clutch extension in place, slip the hose clamps around the pedal from either side, and tighten the hose clamps. When you're done, it will look almost like this. This is shown with the hose clamps still loose for illustrative purposes. When you tighten them down you cannot see them at all. I also did a bit more touch up with the black spray paint (although I didn't take a pic, sorry) and the whole assembly is now virtually invisible!
Attached Thumbnails
DIY: Clutch Pedal Extension-clutchext16.jpg  
__________________

Last edited by Omicron; 11-01-2003 at 02:11 PM.
Omicron is offline   Reply With Quote
Old 10-31-2003, 06:29 PM   #17
Registered User
 
Trader Score: (0)
Join Date: Oct 2003
Location: Mobile, AL
Posts: 288
dude, that's nutz...........hows stability tho? any kind of movement? security?

I'm not sure whether to laugh or applaud!!
oosik is offline   Reply With Quote
Old 10-31-2003, 06:30 PM   #18
Administrator
 
Omicron's Avatar
 
Trader Score: (0)
Join Date: Oct 2001
Location: Boulder County, Colorado
Posts: 8,007
Solid as a rock. I experimented with this quite a bit before I found something I was happy with.
__________________
Omicron is offline   Reply With Quote
Old 10-31-2003, 07:06 PM   #19
100% Italian
 
mikeb's Avatar
 
Trader Score: (0)
Join Date: Jul 2003
Location: orange,ca
Posts: 9,429
talk about DIY
great pics and job
__________________
My Rx8 July 27th, 2003

Friends don't let Friends DRIVE STOCK
mikeb is offline   Reply With Quote
Old 10-31-2003, 07:28 PM   #20
Registered User
 
Trader Score: (0)
Join Date: Sep 2003
Location: chicago
Posts: 54
Send a message via AIM to chinqlinq
Quote:
Originally posted by mikeb
talk about DIY
great pics and job
yeah seriously...looks good imo :D
chinqlinq is offline   Reply With Quote
Old 10-31-2003, 07:41 PM   #21
Registered User
 
highspeed8's Avatar
 
Trader Score: (0)
Join Date: May 2003
Posts: 79
Nice how-to. That gives me some good ideas.
highspeed8 is offline   Reply With Quote
Old 10-31-2003, 07:58 PM   #22
Caution!
 
j1mb0x99's Avatar
 
Trader Score: (0)
Join Date: Jul 2003
Location: Michigan
Posts: 207
Send a message via AIM to j1mb0x99
not bad... not bad at all... I hope no dumb *** tries to get really critical about the looks cause who the hell is gonna look under your clutch pedal?

-JiM
__________________
Nordic Green 6mt, GT & Apearance Packages,
Rotory accents, chaparral leather, spoiler, & Nav.
j1mb0x99 is offline   Reply With Quote
Old 10-31-2003, 08:01 PM   #23
Registered
 
neit_jnf's Avatar
 
Trader Score: (0)
Join Date: Mar 2003
Location: Somewhere in Puerto Rico
Posts: 1,168
Send a message via AIM to neit_jnf Send a message via MSN to neit_jnf Send a message via Yahoo to neit_jnf
Great job!

I'm a little disapointed to see that the RX-8 pedals are not true Aluminum pedals like the FD RX-7 had
neit_jnf is offline   Reply With Quote
Old 10-31-2003, 09:49 PM   #24
Len
Registered User
 
Trader Score: (0)
Join Date: Aug 2003
Location: Ottawa, Canada
Posts: 99
Quote:
Originally posted by neit_jnf
I'm a little disapointed to see that the RX-8 pedals are not true Aluminum pedals like the FD RX-7 had
I'm disappointed too. I hate that wrap-around rubber flange thing, and when I saw the faux-racing pedals I thought Good, they won't fall off like occasionally happened in my old Prelude.


Great DIY, Omicron.
Len is offline   Reply With Quote
Old 10-31-2003, 11:54 PM   #25
Registered User
 
Trader Score: (0)
Join Date: Jul 2003
Location: NC
Posts: 916
Yes great job! I am average height but have short legs and share your complaint regarding the gas and clutch pedal placements. I think I will try your solution. Again, thanks for the great job detailing the mod.
__________________
2004 Red 8, Red/Black Leather, MT
GT, Appearance, Rotary Accents,
Spoiler, 6 disc CD
Delivered 8/25

Added: Front mud guards, strakes, exhaust finishers, and foot lights.
red_rx8_red_int is offline   Reply With Quote
Old 10-31-2003, 11:54 PM
RX8Club
Mazda RX8




Paid Advertisement


 
 
 
Reply

Tags
black, close, clutch, covers, diy, extenders, extension, extensions, hole, homemade, mazda, pedal, pedals, racing, rx8

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is Off
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -5. The time now is 02:28 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
All content Copyright 2007 by Internet Brands, Inc.
Emails Backup