This project takes about an hour (or likely less, if you are familiar with the tools) of active building time plus the time it takes for the glue and varnish or paint to dry. Material cost should be minimal. I happened to have everything in stock as leftovers from previous projects, so practically these cost me nothing.
- 4 pieces of 10x10cm plywood (6mm thick is fine)
- 4 T-nuts with 5mm thread
- Varnish or paint (optional)
- Some skateboad grip tape
- 6.5mm drill bit
Step 1: Declaw T-nuts
Step 2: Cut Plywood
I drilled two 6.5mm holes two both platform pieces. The centers of the holes are on the centerline and they (the centers, that is) must be 14 millimeters apart from each other. The cleats are fastened to these holes.
Use the jigsaw to saw a 5x6,5cm opening to the reinforcing pieces. Note that the reinforcing pieces are not symmetrical! The opening is 5mm closer to the back of the pedal. See attached drawing.
Step 3: Glue & Cleat
After glue had dried, I applied some varnish to the platforms, because I will use them during the winter too. After varnish had dried I fastened the cleats. I pressed the T-nuts to the holes, using brute force, and screwed the cleat tight.
Step 4: Apply Grip and Test
These pedals are not as comfortable as proper pedals. They rotate sideways a bit under the foot, just like the bicycle shoe does in the PD pedal. The only major annoyance is that when I take my foot off the pedal, it immediately rotates upside down.
Step 5: Improve Grip
First I drilled holes that were slightly smaller than the screw core, opened the holes with countersinking bit and screwed in the screws. Driving wood screws right into plywood can make the plywood crack, so always drill holes first. Then I flattened the pointy ends of the screws so that they don't puncture my shoes. I did this with a hacksaw but if you have shorter screws a metal file might be a better tool.
If you don't wish to use a reinforcing plywood piece under the platform, it may be a good idea to use round headed screws instead of countersunk screws.