1/8" x 1.25 aluminum bar stock
3/32 solid aircraft rivets
1/8 " Pop-rivets
Cut Material to rough size- Band saw parts to the approximate size
Fill and grind parts to finished size- Using hand file and grinder, shape the parts to size. The most important and trickiest part is the step that allows part to fit behind the sheet metal lip on the pedal
Pre-fit parts to find best fit for rivets- Trial fit the parts to the pedal to insure that everything will go together correctly, mark with pen and if necessary do a bit more trimming of parts
Drill holes for rivets- Clamp the parts together and Cleco as each hole is drilled
Pre-fit parts again- One more trial fit to make sure everything fits correctly
Rivet small plate to larger plate-We used solid aircraft rivets and a bucking bar with hammer, (This part could instead be bonded with epoxy)
Rivet assembly to pedal-Using the Pop-rivets, install the assembly to the pedal, we again used the Clecos to make sure everything was lined up.
Inspect- Use a mirror and flashlight to look behind the pedal to make sure there is a good bucktail on Pop-rivets and that everything is lined up straight
Last Step- Find a nice canyon to go carve a few heel and toe shifts������
1/29/03 Copyright 2003, skoshiracing