Fitting Wipers, Gearstick and Handbrake | Audi TT Kit Car | PedalBox Episode 64

wipe away your tears because on this episode of pedalbox we're gearing up to add some more important components to the kit car oh my god [Music] the first thing we're going to build is a platform for the gear selector to live on we did have a tunnel to do that job but it was far too big for what we need only having coolant pipes running forwards and backwards on the car we've positioned the gear stick high enough that it's a quick movement from the wheel to the top and back again and we've also raked it backwards so it's a much more comfortable shift rather than having to pull the lever in a very flat angle like this which is just uncomfortable to do so the first thing we're going to do is start welding on a couple of pieces of half inch box to get the basic framework for this platform roughed out coming down from the firewall towards where the tunnel is going to continue here's our platform we've just kind of built it up and designed it in the car and that way we could make sure that whatever flare we had at the bottom wasn't going to be too small to slide the pipes out at a date in the future we don't want these permanently welded into the car that would be a mistake now i designed the top of this so that it would fit between these two m12 mounting holes here and they just fit either side which have some little tabs and they just bolt on really nicely unfortunately i missed and seemed to have added an extra half inch or so onto the top so they no longer line up quite how they should have it's not necessarily the end of the world though i've milled out the heads using the grinder to cut these down in half the whole of the thread is there i'm going to use these as studs they'll go through the bottom of the holes and the whole thing will be mounted onto the top of our tunnel platform like that we'll just weld these bolts on and then cut them down to whatever height we need but it means that we don't have to add an extra platform to mount the studs to we've made it out of the bolts themselves now that the shift is in its final position we're just going to do a quick check to make sure everything works for me so i've pulled the seat forward and installed myself here in the car wheel's nice and comfortable still i've got a short trip to the gear shifter that's all nice and happy my arm doesn't come back into the seat or anything too nasty and when we're up in fifth on the front right of the shifter there i've still got good access to the indicators this is all 10 out of 10 stuff next up we're putting a small crossbar into the outside of the chassis here and that covers the front of it and we're then going to start building the tunnel off the back of the shifter tower here so that we can fit our handbrake the back of the tunnel behind the gear shift is going to have a hand brake on and it's going to sit a little bit lower down so it's not in the way of your elbow when you're trying to shift gears or generally in the way when you're sitting in the car so we've lowered the back crossbar down on this h piece that we've welded in at the back edge of the tunnel and i've got some 800 mil pieces of box which i'm going to weld in to make the flat coming across here but before i do that we need to check two things one is that these center pipes actually fit through this hole and eject out through the front of the car because otherwise we have to cut this out and make a few changes so we'll see what happens but i also want to weld in two cross braces from the inside corner here up to the underside of our chassis rails at the back that hold the engine in and when we lifted the car previously there was a lot of twist and parallelogramming of the chassis now with this in i all of this cage structure i don't expect it's going to do it that much but i would like to add another piece in while i'm here just in case probably not quite as heavy duty as this just another piece of half inch box but we'll get those in test these pipes and then finish off the rest of the [Music] tunnel [Music] i'm tagging in for a bit now because adrian's been curled up in here for two hours and i think it's my turn now we've put a couple little vertical braces in here to support the front of the handbrake because it's actually going to fit onto these two little pieces of bar here so we're going to punch some holes in these two pieces of flat bar get the handbrake mounted up put the seats back in and make sure everything fits and works so you've skipped ahead a little bit here we've got both seats back in we've tested the ergonomics of our new handbrake and even all the way up at the top here it's still kind of usable my arm does dig into the seat a little bit up there but in normal driving it should only come up to here which is fine and for adrian with a seat further back it should be fine for him as well so we're pretty much done in here for now the next thing we want to do is get our gear shifter actually hooked up to the transmission but that does mean mean we need to order some custom three and a half meter long shift cables which we haven't done yet we'll get to that later now we thought we'd be really smart when we went down to a1 to pick up a windscreen wiper motor assembly from a smart car to match our windscreen unfortunately this wiper motor comes from a first generation smart and turns out our windscreen comes from a second generation smart and that they don't quite align as nicely as we would have liked we've put it up so that we can measure how much clearance we have underneath the cowl for the mechanism to rotate around but a much bigger problem than that is this motor sits right over the fuel filler for our tank so we're going to have to move the motor no matter what now i made a bracket that sits on the top of our pedal box or on the front of the pedal box that we can use to bolt on a mount to hold all of this in place and actually moving this motor across works much better with this one it also doesn't leave this arm just kind of wobbling in free space because these pinch down through a nice big 24 mil hole which i've drilled into this piece of plate and i'm going to split this down and we can mount this onto the bottom of the cowl here and it should all fit really nicely but to get our clearances right we're going to have to cut the motor off move some stuff around get this welded on and then see exactly what type of bracket we're going to have to make [Music] now it turns out sunlight is really really useful when you're trying to build a car we spent about an hour and a half yesterday after dark trying to figure out the motion system on this after we moved the motor from here up to the other end and now with the benefit of daylight adrian came out just after lunchtime while i was at work and got it all hooked up in about 10 minutes flat it's really really easy when you've got light it turns out so running the motor now you can see both of our arms actuate we've got no locking or binding or anything in the mechanism and everything's quite happy so that's all good next up we had to figure out exactly where it sat on the car to get the alignment of the wipers on the screen correct and that was a little bit of a back and forward process started out with this bracket here that adrian made up that fits onto the front edge of the pedal box with one great big 12 mil bolt that holds there and the brackets the here on the motor and the middle of the assembly bolt onto both ends of it now with that in place he could locate the ends the actual spindles of the wiper arms themselves and this took a few goes because it turns out when you fit the motor it kind of wants to the whole mechanism sort of tweaks and bends a little bit as it figures out where it wants to sit and actually snap these a few times it's sort of tack them on run the motor they snap off after a few rotations and they sort of settle into where they want to be so now we've got them in the final position they're quite happy there so they we're going to weld those up solid we're going to weld both sides we're going to pop this bracket back on reinforce it a bit more because it now bends quite a lot vertically as this mechanism runs we're going to put another little stay in on the right hand side here to support the motor bracket directly and then we can put the whole thing together for real [Music] well i know windscreen wipers aren't the most glamorous part of any race car project but considering we're hoping to get this thing road legal they are pretty important to us so now that we've got everything back together which is a nice simple rebuild it's only about half a dozen fasteners hold the whole thing together we're going to do a quick test run we've got a couple of leads attached here with a switch and we're going to make sure that the motor and mechanism all works as we hope it should think we can call that a win well it's a couple of successful weekends work finally getting this scuttle panel in as well as the transmission tunnel yep now that we've got the shifter in place we've measured up to figure out what length of new shift cables we need to make this whole thing work it's actually kind of ridiculous three and a half meters of cable to get all the way around across the front down the car and round into the back yeah should mean there won't be any bind in it though which is really really important yeah that's gonna be great for us out on track with the last thing we want is a sticky or notchy shifter we've also got the hydro in which we can start plumbing in the near future because i think we've actually got all the parts that we need for that basically everything for the brake lines and the fuel lines we're just waiting on a couple of fittings so we can start putting that together so hopefully next i'll be either one of those two among a few other bits like the intercoolers which will finally plumb in on camera rather than me just throwing them in the background and going i'll come back to that and then not in the meantime if you like what we're doing please remember to like share and subscribe to the videos i know we say this every time i know you're probably bored of hearing it but it really does help us out with getting more visibility and we're so close to a thousand in fact by the time this goes out we might have even cracked a thousand subscribers which would be awesome that would be great if you would like to buy any of our merch we've got new t-shirts as well as these ones and these beanies ready for winter and you can also jump on patreon.com forward slash pedalbox show and support us there for as little as a dollar a month so with all that said and done it's just time to wave goodbye [Music] you

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