Manky's Pop.

[Manky Monkey]

It ain't that pretty up close mate. Still lots of bodywork to sort out & most of the chassis is still only welded on the top face -once everything's in place we'll strip it all down, (I reckon it'll only take an afternoon), & roll it over to fully weld everything.

[Manky Monkey]

With the back end more or less complete & just waiting on Loony to add the sheetmetal, I've started working my way forwards again. Before he can plan the floor & bulkhead, I need to fit any interior stuff, like pedals & handbrake etc. The bodyshell's only tacked in place on the chassis, so we'll have to start thinking about body mounts too.
The brake pedal & master cylinder are already sorted. Just waiting on Stafford Vehicle Components to supply the hanging bracket for the remote servo & we can plumb the brakes in. The brake pedal comes up through the floor, (or will do once we've actually got a floor), but we decided it was easier to make a pendulum throttle pedal that will hang from the bulkhead. Actually it'll be mounted in a piece of box section, same as the brake one, & hung from the side of the framework that loops under the dashboard. The exhaust system will run under the floor, alongside the chassis rails, so a floor mounted thottle pedal would get in the way.

[Manky Monkey]

We're trying to recycle as much of the original Pop as we can, not because we're trendy green tree hugger types, but because it saves us buying stuff & also cos it's just kinda cool to adapt & re-use the old parts. So I took the remains of the pedals, left over from making the brake one & cut them up.

[Manky Monkey]

Obviously it'd be nice if the 2 pedals are roughly the same height & end up the same distance from my feet, so I shortened the cut up bits & turned the end around to produce this.

[Manky Monkey]

Looks a bit odd turning through so many different angles, but no more so than the original did.
Then I bolted on the end plate & thick rubber "Bulls Eye" pad, supplied by Chris of "Pop Browns", to match the other pedal.

[Manky Monkey]

It needs a short arm above the pivot point, for the throttle cable to attach to, so that it's pulled when the pedal is pressed. So I re-used another part from the original Pop set-up. No idea of the pedal ratio -I tend to work by the try it & see method. The cable appears to move about 2 inches between fully closed & open so hopefully this'll work.

[Manky Monkey]

Once it's fitted to the framework under the dash, the pedal should end up level with the brake one & more or less symetrical to it, the other side of the steering column, as the pedal arm is angled out to one side.

[Manky Monkey]

We'll need to fit a throttle pedal return spring, which Pop Browns also sell, to help lift the heavy pedal to it's resting point. On my way home from Loony's place, I dropped the pedal & a short piece of box section at my mate Reg's house. With luck he'll use the lathe in his shed to produce some bronze or brass pedal bushes, plus a pinch bolt fitting to attach the cable to the pedal arm.

[Manky Monkey]

While I wait for him to do that, I'm going to re-work the steering column drop. I haven't been happy with this since I made it -far too chunky & industrial, even if it is going in an old truck.
The steering wheel sits at the right height & the other end attaches to the knuckle joints & steering box fine, so I need to re-make the drop mount to the same length as the old one.

[Manky Monkey]

I thought it had to clamp around the column, but after checking out other people's cars at shows, most seem to weld tabs directly to the column outer sleeve & bolt the drop bracket to that. So I chopped up my original clunky clamp thing & we'll weld the 2 clamp halves around the column outer sleeve. That should give us something beefier to weld a tab to.
I'll re-use the arms I made before, bolted to the same tabs under the dash, but bring them in tighter together & weld a mounting tab to the point where they meet. I'll probaly make new tabs with 2 bolt holes rather than 1, so the column can't swing from it's mount.

[panthershaun]

looking good mate  racing ahead I see  received my piggy box from Plasticpig today so off up the barn sunday for some major playing around 

[Manky Monkey]

Can't beat a bit of playing around in the shed Shaun.

[Manky Monkey]

Old clamp halves welded around the shortened Moggy Minor steering column outer sleeve. You can see the collapsible section from a VW Beetle I added to the bottom of the column. Not required for the commercial vehicle SVA test, but not a bad idea anyway.

[Manky Monkey]

That gave us somewhere solid to weld a new mounting tab to.

[Manky Monkey]

Then I cut down the arms I made before & we tacked them to another tab. Next I'll cut a triangular infill plate & weld it all together.