Sunday, March 1, 2009

Reparing a worn-out pivot hole in steel

These pictures show how I repaired a clutch pedal with a worn-out pivot hole.

The hole is oval-shaped, which causes the whole clutch linkage to feel very sloppy. Eventually, the clutch would not fully disengage even with the pedal pushed to the floor.

The first step was to bore out the hole to .500" with an end mill.

I cut a piece of 1/2" steel rod to fit the depth of the clutch pedal plate, and brazed it into the hole. I used a grinding wheel to make the edges flush.

Now it is easy to drill a new hole that is the proper diameter

The repair is invisible under a new coat of paint.

The completed pedal assembly is ready to be replaced in the car.

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