How to reattach dead pedal? (pics) - LotusTalk

darkSol · 10-05-2009, 04:19 PM

Ok... at the track 3 years ago my dead pedal fell off when I pressed on it hard while braking.

Well I thought it would be ok... but I can't take it anymore and NEED to brace my left foot/leg against it while driving at the track...

So do I rivet it? Use some more adhesive?

Suggestions?

ZJChaser · 10-05-2009, 04:38 PM

The dealer put mine back on a couple times

The second seemed to do the trick.

darkSol · 10-05-2009, 05:13 PM

Unfortunately my dealer's 500 miles away

Bane · 10-08-2009, 03:29 PM

fitfan · 10-08-2009, 04:44 PM

you certainly don't want to drill and rivet into the chassis main monoque. glue it!

darkSol · 10-08-2009, 07:50 PM

I just used a wire wheel in a drill to scrape all the remaining betaseal off the dead pedal... then I drilled two 1/4 holes in the rear mounting flange (front's too difficult to reach)

I then applied a liberal amount of JB Weld on it and smooshed it into position.

I'm going to let it set overnight and tomorrow drill through the holes into the chassis and put two pop rivets in there to ensure it's not going anywhere.

Thanks for all the help guys!

Done!

Sh4rkattk · 10-09-2009, 03:33 AM

I would not recommend drilling into the chassis.

MNlotus · 10-09-2009, 03:45 AM

Quote:

Originally Posted by Sh4rkattk

I would not recommend drilling into the chassis.

+1

MaineLotus · 10-09-2009, 03:55 AM

Quote:

Originally Posted by Sh4rkattk

I would not recommend drilling into the chassis.

Why not? Remove the interior trim pieces and carpet and you'll find a lot of holes drilled in the chassis. Drilling a 3/16" hole for a rivet is not going compromise the integrity. Glue and rivets is the proper way to attach the foot rest. A chunk of loose aluminum behind the pedals is a potentially bad situation.

TimMullen · 10-09-2009, 08:12 AM

Quote:

Originally Posted by MaineLotus

Drilling a 3/16" hole for a rivet is not going compromise the integrity. Glue and rivets is the proper way to attach the foot rest.

The aluminum of the chassis is actually very thin, and not really a good candidate for attaching pop rivets. The shapes of the various extrusions bonded together is what gives strength to the chassis. Any holes drilled in, and things attached that will stress the rivets/holes is probably not a good idea. Almost all of the rivets in the chassis are not there for structural strength, but were used to "jig up" the chassis - to hold it in position - so that it could be placed in the ovens to cure the "glue".

The proper way to attach that foot rest is to use the proper type of "glue" to hold it in position. If the glue won't hold it, the pop rivets aren't going to either, and when they pull out, you will have caused damage to the chassis.

darkSol · 10-09-2009, 08:41 AM

Well the JB Weld will hold the pedal on for sure... the two small pop rivets are only going to assist in any possible lateral shear. I'll plop a small blob of silicone in the hole and over the rivets afterwards so there's no possibility of moisture infiltration...

The factory BetaSeal didn't hold the pedal on - so that's not an option... in fact it failed in less than 11 months after it was applied at the factory - and there was a LOT of it on there.

More than anything I don't want that pedal to come off again... there's nothing scarier when you're braking HARD downhill from 120mph to 70mph and your left bracing foot suddenly pushes all the way down... and the dead pedal lodges itself underneath the clutch and brake pedals. The driver seat dry cleaning bill was substantial. Never again!

MaineLotus · 10-09-2009, 08:57 AM

Quote:

Originally Posted by TimMullen

The aluminum of the chassis is actually very thin, and not really a good candidate for attaching pop rivets. The shapes of the various extrusions bonded together is what gives strength to the chassis. Any holes drilled in, and things attached that will stress the rivets/holes is probably not a good idea. Almost all of the rivets in the chassis are not there for structural strength, but were used to "jig up" the chassis - to hold it in position - so that it could be placed in the ovens to cure the "glue".

The proper way to attach that foot rest is to use the proper type of "glue" to hold it in position. If the glue won't hold it, the pop rivets aren't going to either, and when they pull out, you will have caused damage to the chassis.

Lotus uses rivets to attach many things to the chassis, and not always with glue. I know because I have drilled many rivet heads off to remove pieces from the chassis. Adhesive usually fails instantly - I'd much rather have the rivets exhibit a loose feeling in this situation. A loose foot rest under the brake pedal is a bad situation.

TimMullen · 10-09-2009, 09:04 AM

Quote:

Originally Posted by darkSol

. The driver seat dry cleaning bill was substantial. Never again!

darkSol · 10-09-2009, 05:58 PM

All done. It's not going freakin' ANYWHERE...

10-05-2009, 04:19 PM	#1 (permalink)
darkSol The Mad Scientist Join Date: Feb 2004 Location: Leawood, KS Posts: 2,698	How to reattach dead pedal? (pics) Ok... at the track 3 years ago my dead pedal fell off when I pressed on it hard while braking. Well I thought it would be ok... but I can't take it anymore and NEED to brace my left foot/leg against it while driving at the track... So do I rivet it? Use some more adhesive? Suggestions? Attached Images __________________ d.a..v...i....d David Thomas Stewart - davidtstewart@gmail.com TVS Supercharged 2005 Graphite Grey Lotus Elise: 286whp, 1786lbs. Drop down a cog give it a handful come round about the roundabout

10-05-2009, 04:38 PM	#2 (permalink)
ZJChaser Registered User Join Date: Aug 2006 Location: Irvine, CA Posts: 3,176	The dealer put mine back on a couple times The second seemed to do the trick. __________________ AJ - Akua Solutions - #128 Lotus Exige - MonkeyWrench Racing - Carbonetic - Innovative Mounts - Toyo Tires - JRZ Suspension - PPE Engineering

10-05-2009, 05:13 PM	#3 (permalink)
darkSol The Mad Scientist Join Date: Feb 2004 Location: Leawood, KS Posts: 2,698	Unfortunately my dealer's 500 miles away __________________ d.a..v...i....d David Thomas Stewart - davidtstewart@gmail.com TVS Supercharged 2005 Graphite Grey Lotus Elise: 286whp, 1786lbs. Drop down a cog give it a handful come round about the roundabout

10-08-2009, 03:29 PM	#4 (permalink)
Bane . Join Date: May 2005 Location: AZ Posts: 3,007 Images: 4	__________________ un-Official LotusTalk Stealth Bulb provider *5* sets in stock!

10-08-2009, 04:44 PM	#5 (permalink)
fitfan Regurgitated User Join Date: Jan 2004 Location: San Diego! Posts: 4,382	you certainly don't want to drill and rivet into the chassis main monoque. glue it! __________________ "...our Germans are better than their Germans."

10-08-2009, 07:50 PM	#6 (permalink)
darkSol The Mad Scientist Join Date: Feb 2004 Location: Leawood, KS Posts: 2,698	I just used a wire wheel in a drill to scrape all the remaining betaseal off the dead pedal... then I drilled two 1/4 holes in the rear mounting flange (front's too difficult to reach) I then applied a liberal amount of JB Weld on it and smooshed it into position. I'm going to let it set overnight and tomorrow drill through the holes into the chassis and put two pop rivets in there to ensure it's not going anywhere. Thanks for all the help guys! Done! __________________ d.a..v...i....d David Thomas Stewart - davidtstewart@gmail.com TVS Supercharged 2005 Graphite Grey Lotus Elise: 286whp, 1786lbs. Drop down a cog give it a handful come round about the roundabout

10-09-2009, 03:33 AM	#7 (permalink)
Sh4rkattk A pound at a time. Join Date: Nov 2007 Location: LA SFV Posts: 583	I would not recommend drilling into the chassis. __________________ 07 Exige S - PhB., TP, TP, LSD, S111 Rear Panel Delete, 2Bular De-Cat, 2Bular 8x24 Burnt GT3, Custom AEM Intake, 6k HID's, Schroth 4pt ASM Harnesses, Milled Steering Arms, Bronze Volk TE37 w/ RE-01R's, Carbon Craftsquare Mirrors, Carbon Front Lip, Benetec Dry Carbon Undertray/Diffuser

10-09-2009, 08:41 AM	#11 (permalink)
darkSol The Mad Scientist Join Date: Feb 2004 Location: Leawood, KS Posts: 2,698	Well the JB Weld will hold the pedal on for sure... the two small pop rivets are only going to assist in any possible lateral shear. I'll plop a small blob of silicone in the hole and over the rivets afterwards so there's no possibility of moisture infiltration... The factory BetaSeal didn't hold the pedal on - so that's not an option... in fact it failed in less than 11 months after it was applied at the factory - and there was a LOT of it on there. More than anything I don't want that pedal to come off again... there's nothing scarier when you're braking HARD downhill from 120mph to 70mph and your left bracing foot suddenly pushes all the way down... and the dead pedal lodges itself underneath the clutch and brake pedals. The driver seat dry cleaning bill was substantial. Never again! __________________ d.a..v...i....d David Thomas Stewart - davidtstewart@gmail.com TVS Supercharged 2005 Graphite Grey Lotus Elise: 286whp, 1786lbs. Drop down a cog give it a handful come round about the roundabout

10-09-2009, 05:58 PM	#14 (permalink)
darkSol The Mad Scientist Join Date: Feb 2004 Location: Leawood, KS Posts: 2,698	All done. It's not going freakin' ANYWHERE... Attached Images __________________ d.a..v...i....d David Thomas Stewart - davidtstewart@gmail.com TVS Supercharged 2005 Graphite Grey Lotus Elise: 286whp, 1786lbs. Drop down a cog give it a handful come round about the roundabout

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