Installation Instructions

(fig. 2) Running Cable Housing Over Top of Main Unit

A: Determine Position for Accelerator Floor Assembly and Best Cable Housing Path

It’s generally better to mount the Accelerator Floor Assembly, AFA further up the vehicle’s accelerator pedal. This way, the cable will be pulling the pedal down closer to pivot point of the vehicles accelerator pedal. Pulling low on the vehicles accelerator will cause a long stroke on the dual controls accelerator.

The , clamp block, CB is used to attach the cable to the accelerator pedal. One or two holes will need to be drilled into the accelerator pedal. One drilled hole is sufficient if pulling close to the edge as shown in (fig. 1). For a two hole installation, the cable goes through the CB , up through one of the drilled holes, loops around, goes down through the other drilled hole and goes again into the CB where the set screw will clamp it secure.

If the AFA is placed under the pedal will it interfere with stroke of the vehicles accelerator? If so, the AFA will need to be moved to the side as shown in (fig. 1).

Determine if it’s going to be better to run the accelerators cable housing under the main unit as shown in (fig. 1) or over the top as shown in (fig. 2).

B: Subassembly of Accelerator Parts onto the Main Unit

Remove bolt from the brake end of the pivot shaft and discard. Fasten accelerator pedal using the large flat washer and threaded hole on the right side of the pivot shaft .

If the cable housing is going to be run over the top of the main unit, the passenger side pulley block will have to be removed from the accelerator plate, flipped around and refastened.

Remove the simple pulley block nut . Place external tooth lock washer over threaded stud (found in bag with accelerator cable). Place accelerator plate and pulley assembly over threaded stud, rotate to the desired position, affix and tighten the simple pulley block nut.

Pull the accelerator O rink off the kits accelerator pedal, put on the thimble end of the accelerator cable and replace the O Rink.

C: Mount the Accelerator Floor Assembly

The AFA can be fastened to the vehicles metal floor board using screws, however due to the comparatively minimum force needed to move the vehicles accelerator pedal there are two simpler options you may want to consider.

If the carpet is tough enough the AFA can be secured to it. Make an approximate ¾ inch slit into the carpet. Remove the L strips from the AFA . Insert the wing of one L strip into the slit and insert the wing of the other L strip in the opposite direction. Reassemble the AFA with the wings of the L strips kept underneath the carpet.

A metal strip can be fastened to the vehicle in an easy location, possibly using an existing stud. The end of this strip would have the AFA attached to it and would be located at the desired position for pulling the vehicle accelerator pedal down. The longer the distance between the AFA and the anchor point of the strip, the larger the thickness and width of the strip needs to be.

D: Complete Final Assembly

The cable housing, CH will have to be fit between the Passenger Side Pulley Block and the driver side AFA . The CH will have to be cut to the length needed. When determining the length of the CH leave 1/2 of an inch to go into each pulley block. Make sure the CH is not cut too short. It should be well seated into the hole at each end without being stretched. It is better the CH is a little longer than too short. Cut the CH using the same procedure as the Main Unit.

Drill holes in the vehicles accelerator pedal, route the cable accordingly and secure the end by tightening the set screw of the clamp block .

FAT7B Dual Control Installation Instructions

Due to the large variance in engineering and the numerous makes and models of cars available to North American consumers, it would be very costly to engineer a dual control system that would readily bolt into any one application. For this reason, it is up to the installer to use some creativity in installing this unit for its intended application.

(fig. 1) Dual Brake Nomenclature: Passenger Side

(fig. 2) Assembly of Cable Thimble End to Pivot Bars

A: Subassembly of the Main Unit

Fasten the cables onto their respective pivot arms (fig. 2). Orient the cable thimble end with the cable end facing down. The cable bolt needs to be threaded into the pivot arm just far enough so that the !$! cable thimble end is still free to pivot. The cable bolt needs to be clamped tight onto the pivot arm using the lock nut and lock washer. This way the cable thimble end is not clamped tight to the pivot arm and is allowed to pivot.

Thread the cables around the pulleys of the main unit according to (fig. 1) (see red parts). Thread the cables into the metal ends of the cable housings and insert the cable housing metal ends into the passenger side pulley blocks of the main unit.

B: Determining Position of the Main Unit and the Best Possible Cable Housing Paths

Find a way to route the cable housings over to the driver’s side. Determine the best position for the main unit. The best position is usually as high on the firewall as possible – the limitation being the heater ducts – and as far to the right as possible – the limitation being the wheel well. Insert a pin into the carpet to mark the position of the upper mounting hole.

Depending on the floor angle and configuration of your vehicle it may be desirable to elevate the lower section of the base. This can be done by cutting and bending a piece of metal or putting a piece of wood that is the proper thickness under the bottom of the instructor’s brake.

(fig. 3) Dual Brake Nomenclature: Driver’s Side

(fig. 4) Brake Clamp Position Options

(fig. 5) Alternative Pedal Clamp Installation for Vehicles with a “U” Shaped or Plastic Type Brake Pedal Arm

C: Fasten Clamp Assembly onto the Brake Pedal

Fasten the Clamp Assembly onto the cars brake pedal (fig. 3 and fig. 4). The alternative clamp arm included in your kit can be used for vehicles with U shaped or plastic brake pedals (fig. 5).

D: Determine a Good Position for the Driver Side Floor Assembly

The Driver Side Floor Assembly should be positioned right or left so that the Pulley lines up with the clamp anvil. Also the Driver Side Floor Assembly should be positioned up or down on the firewall so that it is in a good position to pull the brake pedal down. Turn the Driver Side Floor Assembly so that the hole for the cable housing is pointed in the direction of the intended cable path that was determined in Part B.

E: Determine a Good Position for the Accelerator Floor Assembly

It’s generally better to mount the Accelerator Floor Assembly further up the vehicle’s accelerator pedal. This way, the cable will be pulling the pedal down closer to pivot point of the vehicles accelerator pedal. Pulling low on the vehicles accelerator will cause a long stroke on the dual controls accelerator.

The clamp block is used to attach the cable to the accelerator pedal (fig. 3). The cable goes through the clamp block, loops around the accelerator and goes back into the clamp block where the set screw clamps it secure. One or two holes will need to be drilled into the accelerator pedal. One hole if you plan to loop the cable around the edge of the accelerator pedal. Two holes if you want to attach the cable further inside, i.e., up through one hole, down through the other.

F: Review Positioning and Installation of Sections B, C, D and E

Cable operated Dual Controls were designed to be a universal type of system. However, too many bends in the cable housing path is going to lead to a poorly operating system.

You may consider compromising the positioning of Main Unit, Driver Side Floor Assembly, Accelerator Floor Assembly and Clamp Assembly to achieve a less restrictive cable housing path.

You will also need to plan out how the installation of the parts is going to be done. It’s likely that mounting the floor components in the positions that you want is going to be a challenge. Vehicle components, particularly the steering column, are probably going to be in your way. Take into consideration what is on the bottom side of where you will be drilling your holes. It may be necessary to custom-make a bracket by cutting, bending and drilling a blank piece of metal.  On the passenger side, making a base out of metal or wood, may be better then trying to bolt the dual control directly to the floor.  These custom-made parts can be mounted in the vehicle with fasteners placed in workable, practical, and safe locations. The dual control part can then be mounted to this.

Tip #1: When drilling holes start with a small drill, maybe 3/32: Drill carefully and don’t allow the drill to pop excessively into the other side. It is going to be very difficult to determine what you are drilling into, especially for the first hole. Once the first hole is drilled, you can insert a piece of wire to carefully analyze where you are drilling; thus being assured of drilling the remaining holes safely.

(fig. 6) Tie Cable Housing Into Knot Before Cutting

Tip #2: The Accelerator Floor Assembly can be fastened to the vehicles metal floor board using screws, however due to the comparatively minimum force needed to move the vehicles accelerator pedal there is a simpler option you may want to consider. If the carpet is tough enough the Accelerator Floor Assembly can be secured to it. Make an approximate ¾ inch slit into the carpet. Remove the L strips from the Accelerator Floor Assembly. Insert the wing of one L strip into the slit and insert the wing of the other L strip in the opposite direction. Reassemble the Accelerator Floor Assembly with the wings of the L strips kept underneath the carpet.

G: Install Components and Complete Final Assembly

When finished installing the components, the cable housing will need to be fit between the passenger side pulley blocks and the driver side floor assemblies. The cable housing will need to be cut to the length needed. When determining the length of the cable housing, leave 1/2 of an inch to go into the passenger side pulley block and 1/2 of an inch to go into the driver side floor assembly. Make sure the housing is not cut too short. It should be well seated into the hole at each end without being stretched. It is better the housing is a little longer than too short.

Before cutting the cable housing, tie it into a knot (fig. 6). This will cause the white nylon inner sleeve to retract into the housing. When the cut is complete, remove the knot and the sleeve will protrude back out. It’s important that the nylon sleeve inserts into the inner hole of the driver’s side floor assemblies.

The cable housing can either be cut by grinding with a cut off wheel or can be cut with a hack saw. Either method has its advantages and disadvantages. Grinding makes a clean cut with minimal cutting forces, but you will need to keep things cool to prevent the plastic from melting. For sawing, you’ll want to use a sharp, high pitch blade and support the housing well in a vise.

Fit the cut brake cable housing and route the cable through the Driver’s Side Floor Assembly, the swage sleeve (if you put the swage sleeve on now it will be ready for the final assembly) and up into one side of the clamp anvil. Pull the cable through the clamp anvil to bring the Instructor’s brake pedal into a desired upright position. Bring the end of the cable into the other side of the clamp anvil and tighten the anvil nut.

Drill holes in accelerator pedal as determined in section E. Fit the cut accelerator cable housing and route the cable through the Accelerator Floor Assembly, the clamp block, the accelerator holes and back into clamp block. Pull the cable through to bring the Instructor’s accelerator pedal into a desired upright position, and tighten the clamp block’s set screw.

H: Install Vehicle’s Pedal Supplement Spring (VPSS)

It is very important that the vehicle’s brake pedal / pedals are retracting back to their original positions. Installation of the dual control on the pedal will have applied some force to it, and this force will likely need to be counteracted with the force of a VPSS. Wrap the VPSS Strap around the vehicle’s pedal and secure it with the screw and nut. Find a suitable location underneath the vehicle’s dash to secure the other end of the spring. The ends of the VPSS can be cut and bent into a hook, as required.

I: Install the Swage Sleeve

When the dual control is in proper working order, finish installing the swage sleeve as shown in (fig. 3). Use of this sleeve will aid in the cable pulling in-line with the center of the clamps swivel. A pair of pliers or vise grips can be used to crimp this sleeve.