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arm79
Cruise Moderator
Age:29
Posts: 3474
Joined: 05 Nov 2004
Location: Westside VIC, Australia
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 Posted: Sun Mar 30, 2008 11:15 pm Post subject: |
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I can do it in about 1.5 hours... Mostly cos im highly intelligent and capable... F**k modest too.. 
But depends who you speak to, some will say 2 hours, some will say 8.
To get a dash out, I take it out in a whole unit. Radio, PAB, cluster, everything. Tis a bit heavy, but its only 1 console, 11 bolts and 10 plugs. And the whole thing comes out like they put it in at the factory. Installation is simply reverse of removal.
The pin is held in by 3 tack welds. Pretty pissy. The manual pedal box itself is exactly the same as an auto, just with the pin welded in. And normally they break by ripping the welds out or twisting the pin in the hole so the whole side of the pedal box rips off.
I have a Mal wood pin. And to reinforce it I got one of these 3mm thick steel patio/wood joiners.. You know, a flat wide bar with holes pre drilled. I shaped that to match the side of the pedal box and put that over the pin on the inside of the box and used the pin bolt to hold it on. Put another bolt at the back to keep it straight. Did the job just nicely. |
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ToranaGuy
Fordmods Tyre Shredder
Age:25
Posts: 344
Joined: 08 Dec 2004
Location: Werribee VIC, Australia
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| Posted: Mon Mar 31, 2008 4:19 pm Post subject: |
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My peddle box was broken & torn when i bought my organ donor ED, i tapped it back into shape & welded it back together. Have not had any issues with it breaking again, yet. 12mths and lotsa abuse on!
I did however, tear my firewall about 8cm from around the clutch hole towards the brake booster. That's due to the LPG fitter cutting the hole for the wiring right thru fords reinforcing in the firewall. I pulled the dash out, was fixing aircon at the same time, and tapped it back into place. MIG welded it up like the peddle box, and also fit a 100x40x3mm plate down the firewall, so it won't twist & tear again.
Since i have done this, i can now feel the peddle box flexing when i'm using the clutch briskly. I should have also re-inforced the peddle box while it was out last time! It's a job i would recommend to anyone, but it's also a job you really need to do with the box out of the car, else you risk heat, fire & weld splatter damage to your car. It was really hard welding the firewall without setting the carpet or the heat liner on the firewall on fire! 
Cheers
ToranaGuy |
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frankieh
Fordmods - Getting Side Ways
Age:35
Posts: 743
Joined: 23 Dec 2007
Location: Perth WA, Australia
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| Posted: Mon Mar 31, 2008 6:31 pm Post subject: |
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Interesting..
I'm gonna take a look under my dash tonight..
have to work out what I plan to do..
I have a mig welder myself and can probably make up something to solve all my woes.. won't know till I take a look see.
What I don't really understand.. the manuals were the base models, the auto was the upgrade.. why not just leave the same pedal box in both ?
rgds
Franki |
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Damo
Fordmods - Getting Side Ways
Age:24
Posts: 988
Joined: 25 Apr 2005
Location: Melbourne VIC, Australia
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| Posted: Mon Mar 31, 2008 7:33 pm Post subject: |
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| it is the same pedal box. The manual one just has a few extra bits tacked on so to speak. |
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ToranaGuy
Fordmods Tyre Shredder
Age:25
Posts: 344
Joined: 08 Dec 2004
Location: Werribee VIC, Australia
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| Posted: Tue Apr 01, 2008 10:23 am Post subject: |
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| Damo wrote: | | it is the same pedal box. The manual one just has a few extra bits tacked on so to speak. |
Yes the manual was the base model but almost everyone spec'd the car's up with the auto's at the very least.
frankieh,
The peddle box is the same as stated, and you will see a hole in the side of the peddle box pointing towards the middle of the car. It's here ford tacked on a extra 1mm or so plate to the side of the peddle box, then stuck the clutch pin thru the hole.
If i had of modified mine, i would have made up a 3mm plate of mild steel with a hole in the same spot, and seam welded it to the peddle box. This would stop most of the flex in the box, from the clutch peddle being pressed. The flex is the problem, eventually it leads to cracked / broken welds & torn steel.
Cheers
ToranaGuy |
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destroyer
Fordmods - Getting Side Ways
Age:27
Posts: 473
Joined: 15 Jun 2005
Location: penrith NSW, Australia
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| Posted: Tue Apr 29, 2008 8:26 pm Post subject: |
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| thank god this is here im doing this soon haha in mine and my nephews so fun times ahead |
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ToranaGuy
Fordmods Tyre Shredder
Age:25
Posts: 344
Joined: 08 Dec 2004
Location: Werribee VIC, Australia
View User Gallery (5)
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| Posted: Wed Apr 30, 2008 3:14 pm Post subject: |
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| destroyer wrote: | | thank god this is here im doing this soon haha in mine and my nephews so fun times ahead |
Yep it's a great doco!
If you both love swapping cogs you will find a new love for your fords, i only liked mine before the manual conversion, now i love it. The manual was definitely the one thing the car was missing the most when i bought it. Damn ghia! 
When you do the conversion, think long & hard about which way you will go with the peddle boxes. My EB, i will probably have to pull the dash out again soon to fix the heater box, so i'm thinking seriously about getting another auto peddle box, the mal wood clutch pin & some 3mm plate steel and doing what i should have done in the first place!
Cheers
ToranaGuy |
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