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Tue Dec 08, 2020 11:23 pm

Next step now is to get the clutch cable pedal hook and make it stronger so it will not wear away at the hook.. I know there a couple of people that make this pedal modified but i thought i could make it myself.. i am not great at welding but how bad can it be ? I had a great idea to get some should bolts and oil impregnated bronze bushings that will serve as a bearing so just follow the pics

This pic is from an ad that i saw on the samba and i thought i could make this mod myself so i did just that

The pics below have the right idea but i actually made an error and welded the shoulder bolt on the wrong side of the pedal assembly where the above pics are correct but i will leave them on here so you will have an idea as to what i was trying to achieve

Got it welded into place and now comes the grinding smooth

Welding the stainless steel shoulder bolt and adding the bronze sleeve bushing that will serve as a bearing

Here is a pic collage of it all

Tue Dec 08, 2020 11:43 pm

Adding a grease fitting to the RHD pedal cluster..

Now to tap it for M5

All done

Wed Dec 09, 2020 1:33 am

Now its time to go Sandblasting and Raptor Liner paint

Now comes the Upol Etching Primer.. it comes in a ready mixed can in a quart size and all you have to do is just fill spray gun and paint.. this stuff attaches to the metal and that is it.

Spring Plates get a dose of the Upol Etching primer also just make sure you have clothing on that won't matter what it is .. once it's on it on your clothes there is no way of getting rid of it.

Wed Dec 09, 2020 1:34 am

This is great stuff.... very pleased with it

Wed Dec 09, 2020 4:46 pm

This next product from Eastwood called "Internal Frame Coating" that a friend of mine that restores cars advised me to use and its awesome to seal the inside where you cannot reach... so just chedk this out.

I fed the line into any and all crevaces to seal the inside of the tunnel and the Napoleon Hat section as you can see by the following pics

Shifter Rod

Tunnel

Wed Dec 09, 2020 5:19 pm

I greased the clutch cable tube and accelerator stainless steel tube also so i can install theRight Hand Drive (RHD) pedal assembly... i used all stainless steel M8 and M10 Socket cap bolts for a cleaner look

Wed Dec 09, 2020 6:32 pm

Now to install the brake stop and adjust

Thinking of what to do next

Wed Dec 09, 2020 6:48 pm

Now lets do something creative with bending of brake lines.. i dont want to run the brake line thru the body on top of the floor pan so i will do my best to route this line thru the tunnel which will be no easy feat.

Wed Dec 09, 2020 8:00 pm

I might have mentioned that i wanted to run the main brake line not on top of the pan like most people do but rather thru the tunnel which was work and troublesome but i got it done.. first i had to open the hole wider so my arm could fit

I installed the RHD Master Cylinder i bought from Just Kampers in the UK.. $42.00 + the DHL shipping literally two days almost overnight was like $50.00 for a combined total of $92.00+ which is not bad and it got here quickly

I placed the EMPI Dual Circuit Reservoir Tank to see where i would place the brake line and this what i mocked up

There is my hole in the pic above now comes the front part...

Harbor Freight Tools Brake Line Bending plier

I had to improvise and use a large 26mm socket to make the right radius bends...

Wed Dec 09, 2020 8:17 pm

Here is some more fancy bending and work... not easy.. to maks sure not to kink the line

Just follow the pics... i am sure you will get the hang of it

This line goes to the Left Front Brakes

Now with the RHD Master Cylinder in place and Dual Circuit Reservoir tank

Looks nice doesn't it

I have already routed the line thru the tunnel and fed it out the back thru the inspection cover before i create some dangerous bends.. one wrong move and the line has to come out.. so this requires a lot of patience

What have i gotten myself into ?

Wed Dec 09, 2020 8:48 pm

Wed Dec 09, 2020 9:28 pm

Lets jump to rear suspension which was a pain... it really was... the torsion tubes were a pain to get right since i didnt mark them before taking them out.. they were not easy to take out since if you have followed this thread you would have seent hat this was a rust bucket and those torsion tube rod i dont know what you call them were pretty much welded in from the rust. I used M10 Stainless Steel Socket Cap Bolts on top of the Chrome Spring Plate Torsion Covers

I had to use C-Clamps from HFT to get the spring plates in.. not easy.. i know there is a special tool that i got to see on Manx Club Facebook page but this is what i had to work with

I figured since I eyeballed this that i would have a 2 click drop thus about 3.5" to 4" of drop but i was wrong.. not the best way to do it and i was not going to go thru the trouble of taking all this stuff off to install again.. nah.. let someone else do it if it needs it at the time in the future..