Now, with the new holes drilled, you can tell that the original metal cover plate is going to be too small to cover the holes.
For this you will need to create a new one out of metal. I used a scrap portion of a dash. You can use what ever you like, as long as it is roughly the same gauge as the original.
Here is the original....
Original next to my new one....
Original on top of new one (for size comparison)....
New one installed over plastic mount....
Now, reinstall the mount, pedal assembly, and metal cover in the cab.
You might notice that he firewall is curved in this area, which will make it difficult to install the cable portion of the assembly.
How I overcame this is to move the location of the cable to the left (towards the steering column) until it was on a flat surface.
I marked and cut my mounting hole in the firewall at the same height as the hole in the pedal rod using a 1/2" drill bit, then squaring the hole off for the cable to snap into (*note-I have not made that pretty yet*).
I also went ahead and mounted the cable in the newly created hole.
As you can see in the photos above, the hole in the firewall does not line up with the hole in the pedal rod.
If you were to connect the cable to the pedal, it would be at a pretty bad angle, which could potentially cause the accelerator to stick....NOT GOOD!!
All I had to do is bend the rod over to the left enough for the two holes to line up!
I removed the pedal assembly and placed the pedal rod in a vice.....
I then gave it a few taps with a hammer until I reached the correct angle...
Here is a stock one compared to the one I bent....
I re-installed everything and the holes lined up just fine.
I attached the cable to the pedal assembly and tested it's movement....
"But what about the hole that is left where the rod type pedal used to go???"
I just know someone is thinking that....
Well, remember, I said that was a no modification install (the hole we drilled doesn't count!)....
Simply head down to the Autozone, O'Reilly, NAPA, CB Shop, or communications shop and pick up a rubber plug or a grommet.
Pop that baby in there and smile at your finished project!
**If you are doing a custom job, or if you just want to take the time, you can certainly weld that hole shut with a small patch.**
And I KNOW those bolts are too long. I will replace them later. But for now, they were all I had around!
Thanks for watching.
Tune in next time for another modification by Putter!!!