You're not going to believe this!

benji_ · Post by **benji_** » Tue Jun 13, 2006 6:50 pm

Hi,

For those keeping tabs, my car is STILL off the road (we've now entered wk 7). Went to pick up my baby today, turned up and there was a little tweaking going on with the DV and few other bits. Turns out that the new Helix Organic clutch has a problem. The problem is that the clutch doesn't engage properly because the pedal box is flexing because the springs on the clutch are so strong! Spoken to 'Mardis Gras M/S' and that was the first thing they asked (is the pedal box flexing?). The clutches are pressure tested before leaving Helix and they are very confident it's nothing to do with the clutch. The movement is only about 4mm but that's enough to stop things working properly. Tried a new cable, tried using some extra washers on the bulkhead end but nothing works. The gear box engages when the pedal is about 1ins from the floor, the rest of the pedal does nothing. So the car now has to have the carpet stripped, lower dash and anything that might catch fire when welding removed and have the pedal box wealded into place. Bloody hell!

I spoke to Andy R but he's not had this problem before so wasn't in a position to help. Has anyone else had any problems with this sort of thing?

Cheers

Squaddiemodo · Post by **Squaddiemodo** » Tue Jun 13, 2006 6:56 pm

Damn that bad news

benji_ · Post by **benji_** » Tue Jun 13, 2006 7:00 pm

Indeed. If this doesn't work I really don't know what to do next. According to Mardis Gras there should be 8mm of throw. But as it's all back together we have no way of checking. The pedal box is the only weak link. I reallyhope that's it

benji_ · Post by **benji_** » Tue Jun 13, 2006 7:44 pm

Has anyone done a hydraulic clutch conversion on a 220 T?

Any thoughts?

Squaddiemodo · Post by **Squaddiemodo** » Tue Jun 13, 2006 7:45 pm

No reason why it wouldnt be possible, you would just have to rape an 820 for it, then make up a hose

benji_ · Post by **benji_** » Tue Jun 13, 2006 8:00 pm

Ok, I'll check it out

cheers

syzsounds · Post by **syzsounds** » Tue Jun 13, 2006 8:01 pm

im stripping an 820 with hydraulic clutch my friend ..

Pm's ya daddy ..

5teve L · Post by **5teve L** » Tue Jun 13, 2006 8:10 pm

Could you not extend the yolk/clutch arm that goes into the gearbox,won't need to use as much force to operate, as it will be longer,some of the big power GTTurbo's used to do it with heavy clutches to stop this(& clutch cables snapping alot)
Would have to be strengthened though as the heat will weaken the metal a bit i think.

Steve

214_si · Post by **214_si** » Tue Jun 13, 2006 8:14 pm

my pg1 on my mini has hydraulic clutch so u can also get one from an mgf

benji_ · Post by **benji_** » Tue Jun 13, 2006 8:27 pm

im stripping an 820 with hydraulic clutch my friend ..

Pm's ya daddy ..

PM'd

Could you not extend the yolk/clutch arm that goes into the gearbox,won't need to use as much force to operate, as it will be longer,some of the big power GTTurbo's used to do it with heavy clutches to stop this(& clutch cables snapping alot)
Would have to be strengthened though as the heat will weaken the metal a bit i think.

I'll have to have a chat with the guy doing the work to see if this can be done. Does it work ok?

my pg1 on my mini has hydraulic clutch so u can also get one from an mgf

Nice to know I can get bits from that as well.

Excellent, I'm glad I posted this up now

Cheers guys

220Si · Post by **220Si** » Tue Jun 13, 2006 11:33 pm

your pedal ain't coming off the floor???

have you snapped the pedal? has happen to me

Post by **Cableguy** » Tue Jun 13, 2006 11:36 pm

220Si wrote:your pedal ain't coming off the floor???

have you snapped the pedal? has happen to me

Yes its coming off the floor si , but it does sweet FA after loosing it off the first inch. I.E all the bite is in the last inch.

iainp · Post by **iainp** » Wed Jun 14, 2006 12:06 am

Pedal will snap eventually, bet it's flexing round the first bolt. New pedal helped with mine.

Iain

benji_ · Post by **benji_** » Wed Jun 14, 2006 7:27 am

Nah it's not the pedal. It's the actual bit that's bolted to the bulkhead that's flexing. Where the clutch cable goes through the bulkhead there is nothing to hold it in place. The nearest bolt is in the middle. The pedal box isn't held down right on the edges, and it's that bit that's flexing.

benji_ · Post by **benji_** » Thu Jun 15, 2006 12:41 am

Sorry to waste everyones time but the problem has now been rectified and my baby is now back with me at long last. In the end we tried what 'gttboy' suggested and an extra washer or 2 and the clutch is now fine.

Thanx everyone for your much needed advice and help on this matter.

Cheers

Ben