i just had some aluminum scrap laying around from another project.
heres my process for all those who want to make their own:
1. measure. measure. and then do it again. make sure everything will fit the way you want. i took off the stock rubber covers as a guide, and traced the accel pedal, drawing out what i wanted on paper first.
watch for where you want to drill (or not drill) the pedals, as some places are much better than others avoid the welds on the back and the slope around the edges.
2. once you have the plan, mark up where you need to cut on the piece of metal and cut the metal. i used a jigsaw with a metal cutting blade, and some oil every once and a while so it wouldnt overheat or sieze up.
3. grind down your cuts smooth, or shape the pedal the way you want I made the curve at the bottom with a bench grinder.
4. find the right hardware (bolts, washers, nuts) and plan your drill sizes accordingly. i dont remember what sizes i used...
5. Mark your holes, and tap where you need to, then drill the holes. holes that would hold the bolts i drilled, then used a larger drill bit to drill about 1/2 way into the piece so the head of the bolt would be countersunk and not protruding. For the larger holes i used a small drill bit to make a lead hole, then the larger drill bit to follow. cool off the metal after each hole or it can become pretty fuskin' hot.
6. sand down the whole shabang with some o that metal sandpaper (you dont have to , but i do and it works well, its the grayish stuff, silicon or something, i dunno) be sure to sand down the edges making a kind of bevel. Afterwards i used a block sander and ran it in one direction to get a nice even look on the surface.
7. Take pedals to the car and mark where you need to drill, measure it to be sure. I just marked it through the holes of the pedals. sometimes im too lazy to be really precise. i put some wood under the pedals just in case, and proceded to drill the holes.
8. Attach pedals with bolts, nuts and washers. Drive it around, see if you are happy with your pedals. (i wasn't the first time, so i cut them down to what you see now) adjust accordingly.
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for the accelerator, since i didnt want to drill, i took some galvanized 32 gauge steel since i had it around and cut it to little rectangle bar shapes, then drilled holes where i needed them to clamp on the pedals. then i slipped them over the pedals and tightened down the bolts like mad, i can take a picture if anyone needs this part more detailed, since im bad at discribing it.
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happy building.
