DIY: Clutch Pedal Extension
10-31-2003, 05:03 PM
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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
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
Last edited by Omicron; 11-07-2003 at 02:35 PM.
10-31-2003, 05:04 PM
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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.
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.
10-31-2003, 05:09 PM
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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.
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.
10-31-2003, 05:12 PM
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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.
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.
10-31-2003, 05:16 PM
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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.
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.
10-31-2003, 05:18 PM
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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.
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.
Last edited by Omicron; 10-31-2003 at 05:27 PM.
10-31-2003, 05:21 PM
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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!
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!
Last edited by Omicron; 11-01-2003 at 01:11 PM.
10-31-2003, 08:49 PM
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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 a little disapointed to see that the RX-8 pedals are not true Aluminum pedals like the FD RX-7 had
Great DIY, Omicron.
10-31-2003, 10:54 PM
#25
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.
