Aluminum Pedals Installation

[TKE878]

I just got a set of aluminum pedals of eBay to put on my 01 Boxster S. I'm looking for thoughts from others before I do the install.

Which is best, remove the stock rubber covers on the pedals and install the new ones, or leave the rubber covers in place and drill through them?

Thanks,

Dan

[1schoir]

I just got a set of aluminum pedals of eBay to put on my 01 Boxster S. I'm looking for thoughts from others before I do the install.

Which is best, remove the stock rubber covers on the pedals and install the new ones, or leave the rubber covers in place and drill through them?

Thanks,

Dan

Dan:

Here is a write-up by a poster on PPBB named "The Voxster", who had sent this to me when I was going to install my aluminum pedals:

(I did not use any of the hardware included in the set):

I did use all Stainless Steel.

Oh, tools I used were:

electric drill (regular and right angle)

good quality drill bits

short philips screwdriver #2

normal length philips screwdriver #2

level

ruler

center punch (very beneficial)

masking tape

pen

'C' clamp

5/16" wrench (open and boxed ends)

5/16" socket on a 1/4" drive ratchet

I also used a small drill bit to give me a pilot hole before drilling any of the final holes.

Dead Pedal and Gas Pedal I used #6 1" although I did have to use a #8 1" for the top of the dead pedal as the #6 was not big enough.

For the clutch and brake I used:

6 Flat Philips Machine Screws (6/32x3/4")

6 #6 Flat Washers

6 Nylon Insert Locknut

I preferred the locknut system over nuts and lock washers, but both achieve the necessary results, although I feel more comfortable that the lock nuts will not loosen where the regular nuts may.

Woops I lied, I did do the process a little different, I actually installed the brake pedal completely before the clutch, I lined it up with the gas pedal, then I did the clutch pedal, found that worked with lining it all up. And yes the brake pedal was a pain in the arse.

Best way is to start w/ the brake pedal. It's the hardest (physically as it's hardened steel and does not provide much room to work) but it also has the least amount of wiggle room behind it to put the screws to align and secure w/. So... start there and then align the clutch and gas pedal off of it.

I first put masking tape over the rubber pedal covers and held the new pedal on top of it. Aligned how I wanted it (checking for bolt clearance on the back side). Marked w/ a pen thru the pre-drilled holes onto the tape and took off new pedal I was holding up. Then using a carbide tipped bit (can't remember size), drilled thru the rubber pedal until I hit the steel pedal (just enough to mark it). Next, I removed the rubber pedal cover and center punched each of the 3 marks. Center punching the holes will prevent the bit from wandering when you go to drill thru it. Put the OEM rubber cover back on, applied some loc-tite to the threads of the bolt (don't want 'em coming loose while driving and tightened into place w/ the lock washer and nut.

Next align the clutch pedal off the brake and mark locations on tape. Here you can just leave the cover on since the pedal itself is plastic. Repeat w/ the loc-tite, secure and move on to gas pedal. Gas pedal is tricky as the pedal is thicker........ thicker than the bolts they give you to secure it w/. Tape it, mark and drill. Secure the top screw (easy). Then cuss profusely while securing the bottom left (it's a major PITA so don't give up). You'll have to squeeze in the plastic back of the pedal in until it starts to thread on the bolt. Repeat process on bottom right screw - even more of a PITA b/c you can only get to it behind the left side and can't see a d@mn thing you're trying to do (like see the hole).

Finally, do the dead pedal. On mine, the screw they supplied wouldn't thread (not long enough and wrong pitch) w/ my dead pedal OEM mount. So I ended up using a larger and longer SS wood screw. If like mine, just drill out the recess on the pedal to accommodate your longer/larger screw. The SS wood screw on mine secured nicely into the OEM spot. The other 2 screws they give you just get screwed directly into the dead pedal plastic.

Good luck and enjoy - they're great looking pedals

Regards, Maurice.

[djantlive]

remove the rubber...

[TKE878]

Thanks Maurice,

Just the kind of useful information I was looking for. I was really debating removing the rubber covers. Thanks and very much appreciated.

Dan