Picture of How to Fix Your Dune Buggy's Brake Pedal
Our old dune buggy is a lot of fun to drive. People stare and say "nice ride, man", and it makes you feel like a celebrity, well kinda. So the only bad part about driving the dune buggy is that the pin holding on the brake pedal doesn't like to stay in. So while you're driving and go to step on the brakes, the pedal just falls on the floor and you have no more brakes. That is not fun, and results in pulling the emergency brake to stop yourself.

The way the brake pedal is connected is this: there is a rod coming out of the firewall with a hole on the end. The brake pedal has a slot on the bottom with a similar hole in it. The rod comes out of the wall and fits in the slot on the brake pedal. Then there is a hardened steel pin that goes through the hole to connect them. The problem is that the pin doesn't like to stay, and is easily wiggled out, leaving you with an unattached brake pedal.
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Step 1: Remove the gas pedal

Picture of Remove the gas pedal
On the dune buggy, there is a non-standard gas pedal. I just unscrewed it on one side so that I could unhook the throttle hook from the back and lower the pedal down.

Step 2: Drill a hole

Picture of Drill a hole
Drill a hole through the rod and into the steel pin. It is a relatively small hole. I decided on the size based on the size of the pin that I am going to put in the hole. There was no way I could get a cotter pin in there, so I basically just had to pound a screw in.

Step 3: Pound in the pin

Picture of Pound in the pin
I found a pretty good quality screw that was the right size. Then I ground down the end a little bit so that it was tapered and could fit in the hole better. It was a good tight fit and required me to pound it all the way in with a hammer, so I know it won't easily come out.
kenster8 years ago
It may not come out, but I got a feeling that it willl eventually snap off. The rod pivots on that shaft to some degree and the screw will eventually stress and break. From my way back VW repair days I believs some type of circlip or other clip was used at the outer end of the shaft to hold it in place. You may want to look at another old VW for reference.
Looking at my sand rail the way the screw is set in the pin and linkage, the pin will rotate inside of the pedal assembly, which moves the point of rotation from "Linkage and Pin" to "Pin and Pedal"
EnigmaMax7 years ago
did you make this dune buggy?
hondagofast7 years ago
May I ask, does your camera have macro?
ANDR8 years ago
nice ride man. Im in the process of making a biggy very similar to yours. my 67 engine is in the garage in need of some tlc