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    Pedal Box into a Gemini.

    Dear PF.

    I've been searching but only seem to get answers for Porsche and some guy with a 260 Datsun.
    Long and short of it is this. My Gemini Sedan has an SR20 in it. Because these things are designed for a cable clutch and the SR20 runs an hydraulic arrangement they need some sort of bracketry done up for it.

    A guy I know had one re-made which ended up in my Gemi with some cheap master cylinder and about a year ago it failed. I got around to buying a new one about a month ago and spend a solid day trying to set it up.
    (It's a Wilwood one).

    The way the factory pedal box is retarded. I busted my hands up trying to get it all right which didn't happen and I since haven't bothered with it.

    So I've been humouring pedal boxes. Without asking the facebook Gemini morons and end up hanging myself, is there anyone on here that might have had experience with
    A: Doing such things in an older car or
    B: Setting one up in a Gemini specifically.

    I only really need one for the clutch and brakes. The braking system needs to be setup factory which is the only kicker. The Clutch master previously sat under the dash and I'd very much like to keep it this way.

    The brakes run a factory booster with a large 1inch master on it.
    I'd like to not touch them if possible so I'm not sure if the pedal box would work for braking?

    If there's another way of doing it, I'm open to suggestion.






    BF XR6 Turbo - 2L Turbo TE - 75 TX Coupe - Atlas SS

    - PSN: rotacoupe

    This is obviously assuming all your AUX outputs are doing something. Ie idle control, and the other does water spray, and the other updates your Instagram automatically etc.

    #2
    Yeah i'd be interested to know how to go from a cable clutch pedal box to hydraulic as well. Surely there must be an easy reliable way to do this?

    Comment


      #3
      Look at what people do for the Mk1/Mk2 Ford Escorts - being simile sized and vintage there my be transferable ideas (escorts were also Cable from the factory and most swaps involve Hydraulic).
      ---
      Shed Project: 1994 Laser Lynx with BP-T

      Comment


        #4
        Back in 2001/2002 a mate and I put an SR20 in his Gemini. We used a modified Gemini pedal for the brakes with a master and booster from an early Suzuki Swift/ Holden Barina, because it was tiny. There were no service parts available for the booster back then, which was a pain in the arse when it failed...
        A couple of (at the time well known) shops had a go at making clutch pedals with the master in the engine bay, but none of them ever lasted more than a week before breaking something. At the time, all the aftermarket pedal sets we could find were too big to fit. We eventually used a hydraulic clutch pedal assembly from a forward control van, but I can't remember what type it was. I think it came from a Japanese van, definitely at Pick and Payless around 2002, so probably a Tarago or an L300, maybe a Suzuki Carry. It put the clutch master above and behind the pedal pivot point, and the piston traveled back towards the driver when you'd push the pedal. Most of the assembly ended up behind the dash on the left side of the steering column, with a fluid reservoir in the engine bay and a hose running through the firewall. It was a real bitch of a thing to fit. That Gemini was sex-spec as fuck, it had Enkei G Zeros, A PS2, and tits airbrushed on the back seat .
        Originally posted by Marlin
        Chickens will slip under water in the cover of darkness like a seal team and FUCK YOU UP.

        Comment


          #5
          Originally posted by 080GMH View Post
          Yeah i'd be interested to know how to go from a cable clutch pedal box to hydraulic as well. Surely there must be an easy reliable way to do this?
          Once I've got something solid I can show you. The way they've done mine is make a bracket to the left of the clutch pedal welded some think as plate there and makes a mount for the master.
          Used to work fine till the cheap garbage master fucked out.

          Originally posted by Aaron View Post
          Look at what people do for the Mk1/Mk2 Ford Escorts - being simile sized and vintage there my be transferable ideas (escorts were also Cable from the factory and most swaps involve Hydraulic).
          Yeah sure I'll have a search this afternoon.

          Originally posted by Faux Forg View Post
          Back in 2001/2002 a mate and I put an SR20 in his Gemini. We used a modified Gemini pedal for the brakes with a master and booster from an early Suzuki Swift/ Holden Barina, because it was tiny. There were no service parts available for the booster back then, which was a pain in the arse when it failed...
          A couple of (at the time well known) shops had a go at making clutch pedals with the master in the engine bay, but none of them ever lasted more than a week before breaking something. At the time, all the aftermarket pedal sets we could find were too big to fit. We eventually used a hydraulic clutch pedal assembly from a forward control van, but I can't remember what type it was. I think it came from a Japanese van, definitely at Pick and Payless around 2002, so probably a Tarago or an L300, maybe a Suzuki Carry. It put the clutch master above and behind the pedal pivot point, and the piston traveled back towards the driver when you'd push the pedal. Most of the assembly ended up behind the dash on the left side of the steering column, with a fluid reservoir in the engine bay and a hose running through the firewall. It was a real bitch of a thing to fit. That Gemini was sex-spec as fuck, it had Enkei G Zeros, A PS2, and tits airbrushed on the back seat .
          Oh yeah?
          There's alot of thing wall sheeting on the firewall/enginebay so it'd flex a bit I'd say? Probably why so many broke.

          It sounds a lot like the setup that's in it currently. I meant to grab some pics of it to put up but forgot.

          Got any pics of the Gemi?
          BF XR6 Turbo - 2L Turbo TE - 75 TX Coupe - Atlas SS

          - PSN: rotacoupe

          This is obviously assuming all your AUX outputs are doing something. Ie idle control, and the other does water spray, and the other updates your Instagram automatically etc.

          Comment


            #6
            Yeah that van based setup is similar to the Escort options, except they fabricate an entire pedal hanging assembly designed to do the masters above your toes which then bolts in place of the stock pedal box using stock mounting points. But because the whole thing is built as a unit the flex and fatigue issues are somewhat addressed. Then you use standard generic masters with it (including brake bias setups if you’re inclined.)

            There are a few YouTube and forums with home-modified adaptation of the stock setup which basically looks a lot like building a mild steel box around the stock pedal hanging arrangement, and tweaking the tops of the stock pedals to give the linkage point for the pistons
            ---
            Shed Project: 1994 Laser Lynx with BP-T

            Comment


              #7
              Is a floor mount pedal box feasible? Willwood make a single MC unit, so you could keep the brakes MC as is.

              Comment


                #8
                Originally posted by no13b_Coupe View Post
                Oh yeah?
                There's alot of thing wall sheeting on the firewall/enginebay so it'd flex a bit I'd say? Probably why so many broke.

                It sounds a lot like the setup that's in it currently. I meant to grab some pics of it to put up but forgot.

                Got any pics of the Gemi?

                Thin sheet is fine, as long as you distribute the load. Had many failures due to absolute muppets designing and building junk. Pushrods at 45 degrees to their travel, jumping out of the piston and gouging the bore. Unbelievable junk in hindsight. Sorry, I don't have any pics.
                Originally posted by Marlin
                Chickens will slip under water in the cover of darkness like a seal team and FUCK YOU UP.

                Comment


                  #9
                  I can tell you how not to do it!
                  I installed a Tilton overmount one in our Gemini rally car by chopping up the 'shelf' in the engine bay and making a steel frame to hold the pedals. Brakes were wonderful and so was the hydraulic clutch but it was shit when it rained, rallying at night in the rain with wet feet is not fun.

                  Comment


                    #10
                    Originally posted by Sprinkles View Post
                    Is a floor mount pedal box feasible? Willwood make a single MC unit, so you could keep the brakes MC as is.
                    Yeah this is the point of my question lol. What an MC unit? I'd have to do some measuring to make sure the booster clip thing is able to pull as normal.

                    Originally posted by Faux Forg View Post
                    Thin sheet is fine, as long as you distribute the load. Had many failures due to absolute muppets designing and building junk. Pushrods at 45 degrees to their travel, jumping out of the piston and gouging the bore. Unbelievable junk in hindsight. Sorry, I don't have any pics.
                    Yeah that's what the original thing was. Rubbish. You'd try and engage the clutch and the whole pedal/mount would flex so the master did nothing.

                    Originally posted by Komdotkom View Post
                    I can tell you how not to do it!
                    I installed a Tilton overmount one in our Gemini rally car by chopping up the 'shelf' in the engine bay and making a steel frame to hold the pedals. Brakes were wonderful and so was the hydraulic clutch but it was shit when it rained, rallying at night in the rain with wet feet is not fun.
                    Lol! It's still a "street car" so I need to keep it sorta standard. I.e. not chop the firewall/anything to make this work.

                    That sorta engineering the car might escalate and never see the road again..
                    BF XR6 Turbo - 2L Turbo TE - 75 TX Coupe - Atlas SS

                    - PSN: rotacoupe

                    This is obviously assuming all your AUX outputs are doing something. Ie idle control, and the other does water spray, and the other updates your Instagram automatically etc.

                    Comment


                      #11
                      MC = Master Cylinder

                      Comment


                        #12
                        Ahh!! I get you sorry lol.
                        So I could just but the wilwood pedal for hte clutch on it's own and the brake stays as normal?
                        BF XR6 Turbo - 2L Turbo TE - 75 TX Coupe - Atlas SS

                        - PSN: rotacoupe

                        This is obviously assuming all your AUX outputs are doing something. Ie idle control, and the other does water spray, and the other updates your Instagram automatically etc.

                        Comment


                          #13
                          Originally posted by Aaron View Post
                          Yeah that van based setup is similar to the Escort options, except they fabricate an entire pedal hanging assembly designed to do the masters above your toes which then bolts in place of the stock pedal box using stock mounting points. But because the whole thing is built as a unit the flex and fatigue issues are somewhat addressed. Then you use standard generic masters with it (including brake bias setups if you’re inclined.)
                          The Escort ones work nicely, but they suck to work on (at least ones in caged rally cars with race seats do).
                          Imagination is more important than knowledge.

                          Comment


                            #14
                            Hang on? As I understand it, the hydraulic set up was working fine till the cheap shit master cylinder shit itself, yes? So why not get the cheap shit master cylinder fixed proper good Aussie styles by Power Brakes, Gilles Plains S.A. and be happy?
                            " Racing cars don't have doors. Toilets have doors" : Keke Rosberg

                            Comment


                              #15
                              Yes. Brakeworx at Queanbeyan probably could do it, although I am waiting to get him to do the MC and wheel cylinders for my 2002. Call Trevor.

                              Comment

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