mcramsay
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| posted on 20/12/10 at 06:53 PM |
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fitting Universal pedal box prior to IVA
hey guys this is my first post on this site, so hello to you all! im currently building a (GBSC or Robin hood) Zero. which has the generald brand
spankers 2.0 zetec, jenvey throttle bodies, Innovate LC1 wideband lambda and Emerald ECU. Im aiming to have the build finished by march and ready for
its IVA test.
Whilst going over bits of the car i really am not happy with the GBSC Pedal box. which is essentially 3 rubbishly welded up pedalts fitted
with rubber bushes with a bolt going through them all, the pedals feel really sloppy and just makes the build really amateur looking.
Ive been reserching fitting a universal floor mounted pedal box and i just wanted to show what i was thinking of doing to Comply with the IVA test
before going and spending around £300! i think ive thought of most things and i should be able to comply but im sure some one will be able to point
something out that ive missed! heres my plan!
the pedal will be this:
http://www.compbrake.co.uk/index.php?searchStr=0405&_a=viewCat&Submit=Go
however im not going to use the individual resovoirs due to float level switches required for IVA. so i have found this tandem reservoir which will
supply two master cylinders and has a level switch built in, it also has the test button and digrams printed on which are needed for IVA
http://www.cbsonline.co.uk/2-chamber-fluid-reservoir-flres2-127-p.asp
this reservoir will attach to the cylinders with the following hose (which is certificated for IVA)
http://www.cbsonline.co.uk/brake-fluid-filler-hose-bfhose-3649-p.asp
the only other issue (i think) is the bias bar which accoring to the IVA manual must be lockwired. which can be easily done. failing that Car builders
solutions also do a bias bar locking kit failing that again i can weld and replace the bias bar for the grand sum of £20 after the IVA test.
does this sound like a viable approch to fitting this kind of pedal box?
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gavin174
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| posted on 20/12/10 at 07:03 PM |
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rally design do float switches to fit individual reservoirs..
good price too..
http://www.rallydesign.co.uk/index.php?cPath=562_1357&osCsid=antoubehr2piuncjjug2jgsa74
http://www.essexkitcarclub.com
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wylliezx9r
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| posted on 20/12/10 at 07:08 PM |
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I bought the same pedal box for my haynes roadster but for a cable clutch, had to do a bit of cutting and shutting to get it to fit.
I'm using the master cylinders supplied but im fitting float sensors to comply with IVA, the sensors can be purchased from CBS. I'm not
quite sure about the balance bar situation, ideally it needs to be left unlocked so it can be fine tuned on the brake test at IVA then locked.
I've heard of some IVA test centres allowing this to be done with lock nuts and other who want it welded.
Cheers Dan
I spent a lot of money on booze, birds and fast cars. The rest I just squandered.
George Best
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interestedparty
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| posted on 21/12/10 at 10:20 AM |
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When you go for the IVA test they will test the brake balance at various different pedal pressures, something that isn't possible to test for at
an MOT station, so basically you will have to go in with it set to your best guess.
If the balance bar needs to be adjusted they will probably let you do it there. The problem then comes with the locking. You don't have to weld
balance bars any more but you do have to have it positively locked, nylocs won';t do. Really it needs to be drilled and pinned, but you are
unlikely to be allowed to drill on the VOSA premises.
Probably the easiest and cheapest way to pass the IVA is to assume you will fail on the first try (most people do anyway), adjust the balance if
necessary during that first test, then get it locked off before the retest.
[Edited on 21/12/10 by interestedparty]
As some day it may happen that a victim must be found,
I've got a little list-- I've got a little list
Of society offenders who might well be underground,
And who never would be missed-- who never would be missed!
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stevegough
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| posted on 21/12/10 at 11:51 AM |
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Firstly, I am stunned by the timescale of your plan! You don't actually say when you started building? - Are you serious about finishing by
march ?
I have just IVA'd mine - its taken 2 years - and I probably have more spare time than most guys I know!
I used a pedal box from OBP (optimum balance products) who is a trader member of the forum. I used twin tanks and the level switches from rally design
(see gavin's link) you need to watch the insulation on the wires as mine started to split through being knocked around whilst I was building - I
cured it by a blob of clear silicone where the wires emerge from the unit.
You don't need a 'press to test light' if you use the same bulb as the handbrake.
Photo coming up showing how I mounted and wired the m/cyl/resrs... Also note the label rivetted to the pedal box access hatch IVA - requirment if
you have a bias bar.
 
Description
Now the Bias bar: - It needs to be fixed in position - many more knowledgeable guys on here have said that to weld such a key part of your braking
system is madness - it can weaken the structure of the metal. They brought in welding at the changeover from SVA to IVA. in April '09. It
speaks volumes that in May '09 they updated the manual and REMOVED the requirement to weld!
Get some lockwire and a drill ready for the test day - David, the inspector who did my test told me that the bias bar setting is not as critical as
most people think - he said as long as you have chosen your master cylinder sizes correctly - as long as it is in the middle it should be ok. I set
mine centrally and it didn't need any adjustment.
Unfortunately, mine failed its IVA on several minior points, so it didn't really matter that I managed to snap my drill bits off in the process
of drilling the holes - its a pig to get to!
Finally, on behalf of all the good guys - and gals! on here, a very warm welcome to the best kit car forum on the planet!
[Edited on 21/12/10 by stevegough]
Luego Locost C20XE.
Build start: October 6th 2008.
IVA passed Jan 28th 2011.
First drive Feb 10th 2011.
First show: Stoneleigh 1st/2nd May 2011.
'Used up' first engine may 3rd 2011!
Back on the road with 2nd engine may 24th
First PASA mad drive 26/7/11
Sold to Mike in Methyr Tydvil 19/03/14
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mcramsay
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| posted on 21/12/10 at 11:52 AM |
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i was going to have the braking system of the car set up at a local garage....however CBS also do a bias bar locking kit. to be honest im sure the car
wont pass first time anyway! i have seen thse additional float sensors...how do they fit into the resovoirs and does any one have a wiring diagram?
finally would i need stickers on each reservoir with a brake symbol and type of fluid to be useD?
(i will have been building 2 years in march by the way!)
[Edited on 21/12/10 by mcramsay]
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stevegough
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| posted on 21/12/10 at 12:01 PM |
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quote:
Originally posted by mcramsay
i was going to have the braking system of the car set up at a local garage....however CBS also do a bias bar locking kit. to be honest im sure the car
wont pass first time anyway! i have seen thse additional float sensors...how do they fit into the resovoirs and does any one have a wiring diagram?
finally would i need stickers on each reservoir with a brake symbol and type of fluid to be useD?
(i will have been building 2 years in march by the way!)
[Edited on 21/12/10 by mcramsay]
Oh! - sorry - I got the impression you were in the early stages! You only need one sticker (£1) at CBS.
And you are right - you will most likely fail first time. David quoted that the first - time pass rate is only 5%.
Drill a 10mm hole in the centre of the lid. Tighten the nut.
You then simply wire the two sensors on parallel so that either switch will close the circuit.
Luego Locost C20XE.
Build start: October 6th 2008.
IVA passed Jan 28th 2011.
First drive Feb 10th 2011.
First show: Stoneleigh 1st/2nd May 2011.
'Used up' first engine may 3rd 2011!
Back on the road with 2nd engine may 24th
First PASA mad drive 26/7/11
Sold to Mike in Methyr Tydvil 19/03/14
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mcramsay
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| posted on 21/12/10 at 12:31 PM |
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cheers for that, looks like i will go ahead with that setup then, its a bit cheaper than the other way i had planned! finally before i order what
sizes of master cylinder do you think i should go for as i believe i can chose between 0.625 0.7 0.75 cylinders
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stevegough
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| posted on 21/12/10 at 12:42 PM |
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0.625 and 0.7 are the sizes I have used - the larger is for the rear.
Also you might like to see this recent thread:- http://www.locostbuilders.co.uk/forum/29/viewthread.php?tid=147153
Good luck.
Luego Locost C20XE.
Build start: October 6th 2008.
IVA passed Jan 28th 2011.
First drive Feb 10th 2011.
First show: Stoneleigh 1st/2nd May 2011.
'Used up' first engine may 3rd 2011!
Back on the road with 2nd engine may 24th
First PASA mad drive 26/7/11
Sold to Mike in Methyr Tydvil 19/03/14
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interestedparty
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| posted on 21/12/10 at 01:18 PM |
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quote:
Originally posted by stevegough
Get some lockwire and a drill ready for the test day - David, the inspector who did my test told me that the bias bar setting is not as critical as
most people think - he said as long as you have chosen your master cylinder sizes correctly - as long as it is in the middle it should be ok. I set
mine centrally and it didn't need any adjustment.
Which test centre was that? Drilling specifically not allowed at Leighton Buzzard.
As some day it may happen that a victim must be found,
I've got a little list-- I've got a little list
Of society offenders who might well be underground,
And who never would be missed-- who never would be missed!
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stevegough
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| posted on 21/12/10 at 05:19 PM |
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Chadderton, Manchester. I think it seems to depend on the individual tester?
Luego Locost C20XE.
Build start: October 6th 2008.
IVA passed Jan 28th 2011.
First drive Feb 10th 2011.
First show: Stoneleigh 1st/2nd May 2011.
'Used up' first engine may 3rd 2011!
Back on the road with 2nd engine may 24th
First PASA mad drive 26/7/11
Sold to Mike in Methyr Tydvil 19/03/14
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