Pedal cluster rebuild, God I just love roll pins. NOT!! Options

[sholman5]

Went to replace my carpet and to my what did I see? A greasy, rusty pedal cluster. Decided to tackle this one myself with a little help from a friend. Disassembly was not bad at all. Even the roll pin came out easily with the help of an air chisel. Sand blasted all of the parts, etch primed and painted. I let everything dry for a week. Today started assembling everything. Used bronze bushings, but the greatist fun all day was replacing the roll pin. It took a few hours, but we wanted to take our time and get it right the first. Ended up using a press to insert it along with a drill bit (smooth end) inserted on the opposite side to keep everything aligned. In the end it was very gratifying to rebuild. Not as nice as a bstone piece , but it is clean and functional. Greatful for all of the threads in the Garage forum.

[Dave_Darling]

The roll pin that was supplied with the bronze bushing kits for many years was not up to the job in the long term. It would usually fail in pretty short order and the pedal would start heading toward the floorboard.

--DD

[bdstone914]

The roll pin that was supplied with the bronze bushing kits for many years was not up to the job in the long term. It would usually fail in pretty short order and the pedal would start heading toward the floorboard.

--DD

I have yet to see a failed roll pin after rebuilding hundres of pedal sets. I have even seen sets with a soft grade 1/4 inch bolt used for a roll pin and it did not fail. I have seen shafts crack at the roll pin hole.

@Dave_Darling

[lierofox]

The roll pin that was supplied with the bronze bushing kits for many years was not up to the job in the long term. It would usually fail in pretty short order and the pedal would start heading toward the floorboard.

--DD

I have yet to see a failed roll pin after rebuilding hundres of pedal sets. I have even seen sets with a soft grade 1/4 inch bolt used for a roll pin and it did not fail. I have seen shafts crack at the roll pin hole.

@Dave_Darling

The one on mine snapped apart into 3 separate pieces, sheared straight through it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-18880-1553471579.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-18880-1553471580.2.jpg)

I ended up doing the bolt method instead since it sheared just as I was starting my car and would have left me stranded at work with no other way to drive home. Thankfully work stocks a large supply of Grade 8 1/4" bolts.

To its credit though, I'm using a fairly heavy pressure plate from KEP's clutch/adapter kits.

[bdstone914]

I have yet to see a failed roll pin after rebuilding hundres of pedal sets. I have even seen sets with a soft grade 1/4 inch bolt used for a roll pin and it did not fail. I have seen shafts crack at the roll pin hole.

@Dave_Darling
[/quote]

The one on mine snapped apart into 3 separate pieces, sheared straight through it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-18880-1553471579.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-18880-1553471580.2.jpg)

I ended up doing the bolt method instead since it sheared just as I was starting my car and would have left me stranded at work with no other way to drive home. Thankfully work stocks a large supply of Grade 8 1/4" bolts.

To its credit though, I'm using a fairly heavy pressure plate from KEP's clutch/adapter kits.
[/quote]

That roll pin does not look stock to me. Not enough coils.
Do you still have the broken pin? See if you can file it to test hardness.

[bdstone914]

[quote name='bdstone914' date='Mar 25 2019, 06:44 AM' post='2699751']
I have yet to see a failed roll pin after rebuilding hundres of pedal sets. I have even seen sets with a soft grade 1/4 inch bolt used for a roll pin and it did not fail. I have seen shafts crack at the roll pin hole.

@Dave_Darling
[/quote]

The one on mine snapped apart into 3 separate pieces, sheared straight through it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-18880-1553471579.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-18880-1553471580.2.jpg)

I ended up doing the bolt method instead since it sheared just as I was starting my car and would have left me stranded at work with no other way to drive home. Thankfully work stocks a large supply of Grade 8 1/4" bolts.

To its credit though, I'm using a fairly heavy pressure plate from KEP's clutch/adapter kits.
[/quote]

That roll pin does not look stock to me. Not enough coils.
Do you still have the broken pin? See if you can file it to test hardness.

That type of failure could also be caused by a loose fittment of the shaft to the arm. I sort through arms and shafts to get the tightest combo to reduce the shear on the pin.
[/quote]