Introduction: Custom Pedal Extension
I have a new truck that's a stick shift. I love my new truck! Unfortunately, it has a long clutch. In order for me to fully depress the clutch, I have to adjust my seat uncomfortably close to the steering wheel making the gas and break pedals a little awkward.
After some research, it seemed my choices were between 'pedals in traction' looking extension (which were expensive!) or a block of wood wrapped in duct tape. I wasn't satisfied with either of these options...
This is my solution.
Step 1: Materials and Tools
I did not want to drill into my clutch pedal. Instead I chose to use pedal covers from AutoZone. A side benefit is that it adds a cool, custom touch.
The Materials used:
Pilot Automotive 3 Pedal Cover Kit ($12.99)
14"x 5" of lacing leather (scraps on ebay for about $6.99)
(4) 2" screws with nuts and washers (sized from the kit)
(3) 1 1/4" screws with nuts and washers
3"x 3" piece of scrap metal (cut this off of a defunked pressure washer)
The Tools used:
Spray Paint (Black)
Contact Cement (Barge)
Shoe Polish (Black)
Polishing Brush (or Cloth)
Heavy Sheers (or Scissors)
Standard Screw Driver
Philips Screw Driver
Clutch Pedal Cover (to use as template)
Electric Metal Sheers
Band Saw or Jig Saw
Step 2: Building the Extention
To find the height of the extension that is comfortable, use Styrofoam, wood or other material between the pedal and foot. A guess-ti-mate also works!
Remove the rubber pedal cover from your clutch. Using the rubber cover as a template, trace the shape with a pencil on the lacing leather. Repeat until the height of the extension is reached. 9 layers gives about a 1 1/4 to 1 1/2" lift.
Score both sides of all the leather pieces using either a Dremel or knife.
Place about a pea size of contact cement on one side of each piece of leather and smear towards the edges. ( I used a small scrap of leather to spread the glue around. Let cement dry a bit (about 5 minutes), then line the pieces up and press them together. Do this to all the pieces until you build a 'block o' leather'.
Use a clamp or weight to compress the glued leather block. Let cure at least an hour.
(NOTE: If a Band Saw is available, glue squares of leather together to required thickness then use the template and cut the 'block o' leather' all in one go.)
Center the leather block on the new Pilot pedal cover. Use the dremel or grinder to make the leather block sit flush with the Pilot cover. Make sure there is room for the outside screw holes.
Mark the holes in the center with pencil.
(NOTE: Remember the convex curve of the Pilot cover when drilling).
Drill the leather with a drill bit the same size or smaller then the screws.
Use a drill bit slightly smaller or the same same size as the nuts and counter sink the holes on the back side (the side that will be pressed against the pedal of the car or truck).
Using a cloth or brush, place shoe polish onto the edges of the block o' leather. Rub vigorously to melt and seal the edges and create a nice shine.
Step 3: Creating Support Plate
I used an old broken power washer to get a piece of scrap metal and beat it flat. At about 1/16 " thick I felt it was solid enough to be clamped to hold the extension.
Use the Pilot cover again as a template for the scrap metal. Mark the curve and the holes. Mark a slot of around 1/4" to 1/2"in width from the bottom to about 1/3 of the way from the top.
(NOTE: A cardboard template could also be used to fine tune how the plate will fit behind the pedal. Make sure it slides on from the top.)
Cut the slot using either metal sheers or saw. Use a file to clean the interior edges.
Grind or cut the corners off and finish shaping.
(NOTE: Clean off any rust with steel wool or steel brush.)
Spray Primer on both sides of the metal plate. Let dry.
Spray black paint on both sides. Let dry and cure for at least an hour.
Step 4: Putting Extension Together.
Line up Pilot pedal cover with the block o' leather. Insert screws. Put on washers then hold the nut to the end. Use the screw driver on the screw and feed the nut onto the threads. Tighten up.
Use a pencil or other wedge if you find the nut slipping.
Grind any excess off the screws so they are flush with the leather. This will be against the curve of the pedal on the car or truck.
(NOTE: I painted the top of the center screws black, but it is not necessary.)
Step 5: Installing Extension
Take the new pedal cover with extension, the metal plate, the 4 2" screws, nuts and washers as well as screwdriver out to the car or truck.
Slide the plate cover over the clutch lever behind the pedal.
Place extension on the clutch pedal and run a screw on the top to hold in place. Make sure everything is lined up.
Insert the 3 other screws.
Place washers on the screws, then feed the nuts on by using the screwdriver on the screw. (It make it easier when your doing it blind.)
Tighten all the screws about a quarter turn past tight. Be careful not to tighten too much as it might crack the pedal cover.
(NOTE: I'd advise using either superglue or lock tight to keep the nuts from slipping.)
Step 6: Comfortable Custom and Clean
Install the other pedal covers according to the kits instructions.
There you have i!
Comfortable, custom and clean pedal extension that blend seamlessly into the truck. No one can see there is at least a 1 1/2" lift on the clutch! It's solid, feels stock and makes for a much more comfortable ride!
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