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"FAT" Dual Controls
Installation Instructions

A hardcopy of the installation instructions is provided with each kit we send. We provide you with the following transcript for viewing on-line.

You may also find that our Twin Stop web page on installations will provide some useful ideas and graphics. TS: Maintenance and Installation


F.A. .T. UNIVERSAL CONTROLS
FITTING INSTRUCTIONS
TYPE A QUICK RELEASE PEDALS
INTRODUCTION :
An economical alternative to rod-operated systems becoming increasingly popular with modern vehicle bulkhead design. The type A unit features fully adjustable pedal arms that can be removed from the unit when carrying a passenger and Bowden, nylon-protected chromium steel cables. The unit can be refitted when the vehicle is changed, usually only requiring replacement cables at a fraction of the cost of rod-operated systems. The cable controls can usually be fitted in 2-3 hours according to vehicle type.
THESE INSTRUCTIONS MUST BE FOLLOWED CAREFULLY! Please read in full before fitting.

Dual Control Installation
ON ARRIVAL CHECK ALL PARTS :

I x DUAL CONTROL UNIT
2 x PEDAL ASSEMBLIES
I x CLUTCH RETURN SPRING
2 x PULLEY ASSEMBLIES
2 x VEHICLE CONTROL PEDAL CLAMPS
2 x OUTER BOWDEN CABLES
2 x INNER BOWDEN CABLES
I x IOmm BOLT, NUT and 2 x WASHERS
2 x 8mm BOLTS, NUTS and 4 x WASHERS

PLEASE CONTACT YOUR SUPPLIER IF ANY PART IS MISSING. RETAIN PACKAGING.

You will need the following items to fit the unit:
Socketslspanners: IOmm 13" 14" 17". Steel drills 8.5" and 10.5". Hammer and punch or pilot drill (2-3"). Drill collar. Hacksaw or high tensile wire cutters. Allen key 8mm, Stanley knife or similar, rule, grease, white correction fluid or marker pen, string.
Dual Control Installation

PREPARE DC unit:

Remove cover plate and pulleys. Check 4 x pulley support bolts are secure - tighten if necessary and then replace pulleys. Tighten nuts on top puIleys.

DO NOT replace cover plate yet.
Lubricate swivel joints for clutch and brake pedals.

Check outer cable nipples fit into sockets smoothly. Clean off excess paint if necessary.

Rebore 10.5" holes (A and B) if necessary to remove excess paint.
Dual Control Installation Make sure that pedal stem can be inserted and removed easily from the pedal stem support. If necessary, clean off excess paint and lubricate.

Lubricate adjustment screws on both pedals.

Lubricate all nuts and bolts for ease of fitting.
page one

Dual Control Installation

PARTLY ASSEMBLE THE DC UNIT:

Remove clamping bolts. Secure loop of inner cable to pedal support between the two washers. Ensure that cable loop can move freely after tightening the locking nut.

Feed inner cables around both pulleys. Ensure that cable guards do not hinder free movement of cables.

Depress DC clutch pedal and clip end of clutch return spring into the notch on the pedal.

Replace cover plate and tighten nuts.

Attach DC pedals. If necessary tie the DC clutch pedal temporarily to the lower pulley bolt with string.
FIT DC UNIT:

Position the DC unit under the dashboard so that the DC pedals will be at about the same height as the vehicle controls. It may be necessary to add a block of wood fixed through 10.5mm hole B (or weld a metal support) to support the DC unit at the correct height. Make sure the DC unit is positioned so that:
The DC pedals can move freely and sufficiently to operate the vehicle controls.
There is enough foot space above the pedals.
The Bowden cables can be fitted with only ONE bend in their length. Note that there is a danger of friction and the cables snapping if the cable has an 'S' bend.

Mark the position of the 10.5mm hole A using white correction fluid or marker pen. Check behind the carpet for cables and that the position of the marked hole is suitable:
Check behind bulkhead for cables, pipes etc.
Check that the hole will be accessible to tighten the nut.

With a sharp knife, remove a small section of carpet and underfelt. Mark the position for drilling with a punch or pilot drill and check position again behind bulkhead for pipes, cables etc.

Drill hole to 10.5mm diameter using drill collar if necessary to avoid damage to carpet or potential damage behind bulkhead. Secure the DC unit with IOmm bolt, nut and washers.

FIT DRIVER'S SIDE PULLEYS:

Fold down or remove carpetlunderfelt behind vehicle controls. Decide on position of pedal clamps and pulleys:
The cable locking ring MUST be on the right side of the pedal clamp and to the right of the vehicle control pedals.
The pedal clamps must NOT hinder the driver's feet to much.
The vehicle controls must be able to move fully and freely without interference from the pulleys or pedal clamps.
Do NOT FIT PULLEY DIRECTLY BEHIND VEHICLE PEDALS!
Dual Control Installation
page two

Dual Control Installation Fit the clutch pedal clamp.

Check pedal clamps for any sharp edge that could wear cable. File smooth if necessary.

Loosen bolt on pulley block hinge. Push down vehicle clutch pedal and position the pulley so that the outer cable can enter the socket on the pulley without bending. Mark hole C on the bulkhead. Check that it will be safe to drill, and drill with pilot hole punch before drilling to 8.5 mm.

Adjust angle of pulley block hinge so that inner cable will run with minimum vertical displacement when vehicle control is operated. Tighten hinge and fix the pulley block in place with 8mm bolt, nut and washers.

Repeat the above procedure to fit the pulley block for the vehicle brake pedal.
For ease of access it may be helpful to connect the cable for the clutch and hold the vehicle clutch down by means of the DC unit whilst drilling for the brake pedal.


Dual Control Installation
FIT THE CLUTCH CABLES:

Fit the outer cable nipple into the socket on the DC unit. Avoid bending the outer cable and mark correct length (including pulley block socket) with correction fluid.

Remove outer cable from vehicle and tie a loose knot as shown on right. Secure the knotted cable in a vice and cut to length, file any burr as necessary.

Untie the outer cable which will allow the inner nylon lining to project.

Cut the nylon projection to 10 mm. Strip the outer cable cover by IOmm so that it will fit the socket correctly.

Reposition the outer cable on the DC unit and feed the inner cable through it and through the pulley block.
Dual Control Installation


Secure the cable to the locking ring as follows:

Push the cable through the groove on the locking ring (towards rear of vehicle).
Push vehicle control down slightly and pull cable tight. Tighten locking nut (finger tight only).

Untie string from DC unit.

Make sure the vehicle control returns to full height then pass cable back through locking ring (to front of vehicle) and tighten fully.

Repeat the procedure for the brake cables.

DO NOT CUT INNER CABLES TO LENGTH UNTIL VEHICLE CONTROLS AND DC UNIT FULLY TESTED.

ADDITIONAL NOTES

If necessary the pedal clamps / pedals can be shortened and rebored to suit your vehicle if they are too big for the vehicle controls. If necessary an additional helper spring can be added to ensure the vehicle clutch returns to full height. Drill a small hole through the vehicle clutch pedal arm and attach a spring to this and a suitable solid fixing under the facia.
Dual Control Installation


Some vehicles (e.g. Ford) have 'U' section or plastic vehicle control pedals so standard pedal clamps do not fit. Alternatively, the pedal clamp can be modified with a right-angle bend and drilled with a 6mm hole. The clamp can then be fitted by drilling the vehicle pedal arm with a 6mm hole and fixing with an M6 bolt and nut to the pedal.
page three

Attaching the accelerator: page one


1 original accelerator
2 small pulley-wheel
3 inner (2mm) accelerator cable
4 Fixing under carpet 5 Drilling 6 Using bolt and strip
7 existing bolt (example)

Dual Control Installation Determine the stroke of the accelerator (acc.) and position of the (small) pulley-wheel, make sure that the acc. will not be hindered and can move free.

If the stroke of the acc. does not allow the pulley-wheel to be placed under it: you can move it up or put it just on the side.

It is better not to pull to low on the acc. to avoid a long stroke on the accelerator on the dual control.
4 Fixing the small pulley wheel.
There are some options to fix the small pulley-wheel. The easiest way is to put the two L shaped strips behind the carpet if this is strong enough to keep the pulley-wheel in place when accelerating on the dual control. Slide the strip under the carpet, one to the right, the other to the left side.

5 An other option is to drill a small hole (3mm) and fix one of the L shaped strips to the floor with a self tapping screw, keep the pulley wheel above the carpet.

6 An option that is used often is to find an existing bolt close to the accelerator make and bend a strip from that point, to arrive at the point where you want the pulley- wheel to be. The longer the strip the thicker the steel you should use.

Attaching the accelerator: page two


Attach on dual controls side the cable thimble by hooking in on the accelerator.
The cable will stay in place but is easily detached when the car is privately used or in some counties during the exam it should be disabled.
Run the cable over the pulley wheel trough the Bowden cable to the small pulley wheel on the side of the original accelerator.

Dual Control Installation
Follow the instructions as in the clutch or brake cable fitting for adjusting of the length of the Bowden cable.
The small clip provided with the 2mm stainless steel cable is to be used to attach the cable on/through the accelerator.

Dual Control Installation

Sample of the attaching the cable to the accelerator pedal, note that if you pull low the stroke will be large on the dual controls side.
The accelerator pulley wheel on the dual control can also be fitted so that the bowden cable runs over in stead of under the dual control. Attach the pulley wheel and plate upside down to the dual control, adjust the direction of the cable attachment.
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