Well that's annoying. :)
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Well that's annoying. :)
So toying with the brake pas box, I figured it's worth checking if my set up will really support it.
Current pedal setup:
http://iainel.co.uk/images/forums/NovaWIP2b/217.JPG
http://iainel.co.uk/images/forums/NovaWIP2b/218.JPG
Yoinked out:
http://iainel.co.uk/images/forums/NovaWIP2b/219.JPG
And what I was interested in, some measurements of the brake pedal:
http://iainel.co.uk/images/forums/NovaWIP2b/220.JPG
http://iainel.co.uk/images/forums/NovaWIP2b/221.JPG
Now i've followed this tech advice on the Wilwood website: http://www.wilwood.com/TechTip/TechPedalTip.aspx
If my understanding is correct, 19cm between pivot and pedal and 4.5cm between pivot and connecting bar gives a pedal ratio of 4.2:1.
On the last pic, if I drill where the white dot is (approx 3.1-3.2cm) that'll give the ideal non-servo-assisted brake pedal ratio of 6:1. So assuming that'll operate the set up properly, who know; I'll have to get a bias box and see how it goes.
I think (might have imagined it though lol ) Ben Spencer (boffer8) might have altered the pivot on his when installing a bias box, might be worth a shout?
I like the the bushes apage back are 1peice.
I have a nova pedal box fitted in mine not the corsa one so its a little bit different to be honest due to the how the standard pedal bar works.
You could redrill it there giving the correct pedal ratio but it also means that the pedal position will change (in relation to other pedals) so you might need to be wary. Worth a go though as it wont weaken the pedal vastly drilling where you are thinking looking at your pics and it would help the feel massively as mine is like pushing a brick wall but im now used to how it is so like the feel of it.
If i was you, whist it was out re-drill it, put it back in and they you can try the standard position back to back with the new one and choose which you prefer...
Thanks Boffer, I received some good advice regarding pedal ratios on PistonHeads actually, my basic measurements may well not be as accurate as I hoped: http://www.pistonheads.com/gassing/t...+modifications
End of the day it's a hacked about Corsa set up against an OE clutch and accelerator pedal, both with their on pivot points, so I just get used to how they feel against eachother as it'll never be as good as a proper pedal box which I just don't have the room for without redesigning my steering, seating and shifter arrangement.
I think redrill and fit is the way forward yeah, hopefully have some updates over xmas when I come to fit my bias pedal box.
I never heard a murmur from you when I was touching your bushes, they felt so good and you seemed to enjoy yourself. It was all a bit tight but with lots of lube and the correct toys they all slipped in eventually which left you with a huge smile and feeling of satisfaction.
You got that pedalbox in yet?
He's not hardcore enough for a real man's pedal box mate!! lollollolQuote:
Originally Posted by Harvey
So with the bushes fitted, I went about refitting the suspension. Rear beam slotted in lovely
http://iainel.co.uk/images/forums/NovaWIP2b/222.JPG
Front bushes posed a problem as the original ones were only 50mm wide, which is actually 2mm too narrow:
http://iainel.co.uk/images/forums/NovaWIP2b/223.JPG
The new bushes are the correct 52mm:
http://iainel.co.uk/images/forums/NovaWIP2b/224.JPG
The chassis had been pinched in by doing up the old bushes, meaning the new ones were miles away from fitting (well, 2mm to be precise):
http://iainel.co.uk/images/forums/NovaWIP2b/225.JPG
This was opened up with a large threaded rod and nuts, wound out from the inside to bring the chassis back into shape:
http://iainel.co.uk/images/forums/NovaWIP2b/226.JPG
Easy job, new 280mm discs for the Wilwoods
http://iainel.co.uk/images/forums/NovaWIP2b/227.JPG
Or so I thought, even those were a faff and had to take the spigot rings from the old discs...
http://iainel.co.uk/images/forums/NovaWIP2b/228.JPG
...And press them into the new ones
http://iainel.co.uk/images/forums/NovaWIP2b/229.JPG
Calipers got tarted up, purely cosmetic refurb as in full working order
http://iainel.co.uk/images/forums/NovaWIP2b/230.JPG
Stripped
http://iainel.co.uk/images/forums/NovaWIP2b/231.JPG
High temp red from Halfords, isn't very red, so a few layers of that
http://iainel.co.uk/images/forums/NovaWIP2b/232.JPG
Then a coat of Vauxhall flame red, hopefully it won't burn off
http://iainel.co.uk/images/forums/NovaWIP2b/233.JPG
Fitted
http://iainel.co.uk/images/forums/NovaWIP2b/234.JPG
Onto some new shiny bits, I purchased a Corsa brake bias assembly from Harry Hockly
http://iainel.co.uk/images/forums/NovaWIP2b/235.JPG
First problem to overcome, the drop on the original Corsa set up was about 10-11cm
http://iainel.co.uk/images/forums/NovaWIP2b/236.JPG
The Hockly item was about 6cm so needed a threaded extension piece and extra rod to reach the pedal
http://iainel.co.uk/images/forums/NovaWIP2b/237.JPG
Using Wilwood master cylinders, the push rods were far too long to actually bolt together
http://iainel.co.uk/images/forums/NovaWIP2b/238.JPG
So both of these got cut down
http://iainel.co.uk/images/forums/NovaWIP2b/239.JPG
All built up on the bench, with 0.625 and 0.7 cylinders for front and rear respectively
http://iainel.co.uk/images/forums/NovaWIP2b/240.JPG
Slightly quirky sideways fitment, luckily the clevis have enough free play to operate this way (as the pedal pivots at 90 degrees to the assembly pivot)
http://iainel.co.uk/images/forums/NovaWIP2b/241.JPG
2 new braided lines to mate up to the original braided lines
http://iainel.co.uk/images/forums/NovaWIP2b/242.JPG
Couldn't be bothered with the manual brake bleeding so took one of the reservoir caps and popped off the internal splash guard
http://iainel.co.uk/images/forums/NovaWIP2b/243.JPG
Drilled a 10mm hole
http://iainel.co.uk/images/forums/NovaWIP2b/244.JPG
Which allowed me to use the Eezibleed pressure bleeder
http://iainel.co.uk/images/forums/NovaWIP2b/245.JPG
Finished
http://iainel.co.uk/images/forums/NovaWIP2b/246.JPG
A quick test drive up the garden proves it works although braking was incredibly poor.. Hopefully due to the new discs so will bed it all in and see where I'm at.
Bigger legs needed :-)Quote:
Originally Posted by Iain
Paul..
Ha - I did exactly the same to bleed mine - worked a treat.
And initially, the bias box will feel like nothing's happening - especially if you've got pads that need heat in them to work... I regularly get into the Nova out of a normal car and nearly sail through junctions, read-faced and sweating! lol
I drove at probably less than 10mph and struggled to stop within a 3 metres, need to bed stuff in properly and see where I'm at. Got Mintex 1144s in at the mo.
Wont the pressure just blow the tape off?
I have a new cap on order, however the reservoir isn't pressurised, the master cylinder just draws in what it needs.
Oh ok, i thought the bottles would be too. Thank you.
Well my issue was pressure bleeding from a dry system, there must have been tonnes of air in the master cylinder (between the push rod and outlet I imagine).
What you're supposed to do is something called 'bench bleed' the new cylinders; plenty of resources online about doing this.
So instead of removing them from the car, I got them level and looped my new lines back into the reservoirs:
http://iainel.co.uk/images/forums/NovaWIP2b/247.JPG
Then topped the brake fluid up to create a looped system
http://iainel.co.uk/images/forums/NovaWIP2b/248.JPG
Lots and lots of pumps of the pedal later, I've reconnected up the system and pressure bled as before. The cylinders now travel a hell of a lot less and the pedal moves lots less too, much more like I was expecting it to.
Test drive later to bed in the front pads and find out if my pedal ratio is usable...
Glad I asked if you'd bled them up okay ;)
Southie wins a gold star.
Yes, get in whoop : dancing :Quote:
Originally Posted by Iain
Test drive successful, I could get the brakes stinking to bed them in. I can only lock the fronts with the bias all the way forward though. Going to re-design the pedal assembly under the battery tray to give a better brake pedal ratio, more updates soon...
Yay they work.
Good to see this is still an on-going project!
Lucky on the Donny off that the gravel did its job
I also did exactly the same on the same corner lol
Had gravel rattling in the chassis rails for about 2months after.
This thread lacks Volvo
Sorry Will, presenting the 2016 trackday support bus lol
http://iainel.co.uk/images/forums/Mi...62549.jpeg.jpg
At least its got a bit of GM in it.
Why that old Volvo then?
My E34 525i saloon wasn't cutting it for loading space and some idiot had lowered it which wasn't helping the towing.
This has a massive loading space for wheels, tools and also sleeping in, good torquey 2.3 turbo lump for towing, RWD, bit tatty so no worries about dinging it and most importantly cheap as chips lol
Fair enough.
Epic machine. I miss my 850 T5
Had a read from about page 250 there some very good work has went into this, lucky in that last video I would have needed a change of trousers after that. Keep up the good work
Thanks mate appreciate the comment.
OK so I had my brakes set up roughly working, but it wasn't a great pedal feel again. I had to address the pedal ratio problem.
Old pedal assembly out:
http://iainel.co.uk/images/forums/NovaWIP2b/249.JPG
Now we all know the issues with fitting a standard Corsa pedal into a Nova;
http://iainel.co.uk/images/forums/NovaWIP2b/250.JPG
What I really need to do is straighten the pedal, and move the pivot point up on the housing, resulting in a longer pedal and better pedal ratio:
http://iainel.co.uk/images/forums/NovaWIP2b/251.JPG
This is achievable since the pedal box rod is a lot smaller than a standard Corsa rod, so for max tweaking I got a selection of clevises (aftermarket, Nova and Corsa ones)
http://iainel.co.uk/images/forums/NovaWIP2b/252.JPG
Needed the longest possible in the end:
http://iainel.co.uk/images/forums/NovaWIP2b/253.JPG
This looks like a bodge job but it's all strong and safe, and is in fact the second one I've made (did a prototype version before this for testing)
http://iainel.co.uk/images/forums/NovaWIP2b/254.JPG
Difference to standard:
http://iainel.co.uk/images/forums/NovaWIP2b/255.JPG
Needed adjusting down on the clevis in this pic, but it all lines up fine:
http://iainel.co.uk/images/forums/NovaWIP2b/256.JPG
The other problem I had was the rear was constantly locking up no matter what I tried, so I've swapped the .7 rear cylinder out for a .75 one:
http://iainel.co.uk/images/forums/NovaWIP2b/257.JPG
To save cutting another down, I've swapped the push rods over:
http://iainel.co.uk/images/forums/NovaWIP2b/258.JPG
Just need to remove the small circlip:
http://iainel.co.uk/images/forums/NovaWIP2b/259.JPG
And the eagle eyed have noticed I've removed the pedal switch holder, so I'm now running a bolt that replaces the banjo bolt on the front master cylinder, that operates the brake lights circuit:
http://iainel.co.uk/images/forums/NovaWIP2b/260.JPG
And it's got a new windscreen due to a few chips in the old one:
http://iainel.co.uk/images/forums/NovaWIP2b/261.JPG
http://iainel.co.uk/images/forums/NovaWIP2b/262.JPG
Nice bit of re-engineering there. Like the banjo-sender too. Keep it up
I thought you were meant to be working from home not updated your car thread?!?
Love the pedal work.
Can you index this thread please Iaiyn. I'm tired of searching through it to steal your ideas.
Gotta earn the theft by wading through 300 pages of waffle.
ha glad it's not just me.Quote:
Originally Posted by 8valve-craig