Greasing Europa pedals

[shootingsight]

My pedal assembly was rusted solid, but after some torch, some penetrating oil, and lots of working back/forth, I finally got it freed up well enough that it will be re-used, rather than spending a lot of time trying to refabricate something from scratch.

Question, how to lube it?  I could dunk it in a pan of oil as a minimum, but am looking for a cleverer solution (more clever) to inject grease in there.  I think even a small zerk fitting in the outer sleeve is too long, unless I weld a collar on the outside of the outer tube.  Or maybe fab a bolt-on collar that will force grease into a joint before I remove the collar ...

Does anyone else feel this need, and has anyone else solved this problem?  Or is it a problem?

[shootingsight]

I was also thinking I could drill a hole all the way through the outer and inner tubes, then rotate the pedal 180 degrees so the drilled holes do not align, and pump grease into the inside tube after plugging one end.  It'd waste a little grease, but not much.

[BDA]

I haven't felt the need to do that but I'm not sure it isn't a good idea (enough negatives for you?!). I have seen where one guy did put a grease zerk in his but I'm thinking he either took his apart and installed the zerk before he reassembled it or he might have made a new assy. on his own.

I would rotate the brake pedal 180° and then drill the hole for the zerk all the way through both tubes. Then rotate the brake pedal back and inject the grease. Of course, you'd want the zerk where you could get to it with the pedals in the car. I think that's what you're proposing, right? You'd probably get a little grease to squeeze out the end. You'd want to be prepared for that. On the other hand, I doubt you'd ever need to reapply any grease.

[dakazman]

  My pedal assembly was in a sad state also . Many years ago I removed the assembly and took it apart. I still have it bagged up in that state . I can post some pics tomorrow.
  Serge did a you tube video on his rebuild. It may be worth checking out.
Dakazman

[BDA]

Here it is: https://www.youtube.com/watch?v=4DMYA8ojESo

He's building an S1 but what he did should translate pretty easily.

[jbcollier]

I fit grease zerks to my fabricated pedal assembly. 

[JR73]

I too have grease nipples on my fabricated pedal assembly - Worth doing in my opinion

[dakazman]

 This is the current state of my pedal assembly. Just as bad as I packed it up. It will give you an idea of the dimensions of the materials that your going to drill thru.
 My attempt is going to spread the spacing out a bit more to accommodate my extra wide feet.
If I fail Pegasus racing may have a suitable expensive replacement.
Dakazman

[dakazman]

After tearing into the pedals I found the brake lever section is sleeved with a 2 bushings. Extending Approximately 1/2” from both ends.  If you drill into the base stay more to the center of the arm. Or assemble. So you get into that slight cavity.

[4129R]

The pedals rust if the screens leak. This also damages the dashboard.

Moral of the story, make sure your screen does not leak, or keep it in a garage and don't drive when it rains.

[shootingsight]

I got my pedals freed up.  Overnight soaking in penetrating oil and a lot of elbow grease going back forth for an hour, gradually increasing the distance it would travel.  So now it goes full circle, albeit with a slight crunchy feel from the rust in there.

OD of the sheath is 1", OD of the inner tube is 3/4", allowing for a gap, somewhere around a 0.100 thick wall.

I found a source of grease fittings that are made to pound into a straight hole, rather than screw in.  It takes a 3/16" hole, and the shank goes in 3/32, so just shy of the 0.100.  I can cut the hole with a 3/16" end mill, so it won't go through the inside tube.  I'll post pics once it's done.

[jbcollier]

For myself, if it was rusted solid, it’s done.  The fact it is crunchy in there still is further proof.  I rebuilt my own using the old pedals welded to new tubing and shafts.

[Certified Lotus]

I disassembled my pedals, media blasted them, painted the external parts and heavily sprayed the internal parts with graphite. Works great.

[BobW]

I just lubricate mine lightly with an oil can. It's not a task that needs doing often.

[dakazman]

   Just “almost “ finished my pedal assembly mod / rebuild.

http://www.lotuseuropa.org/LotusForum/index.php?topic=2058.630

I  posed a question there on where your pedals are when you drive. Another question is which way would you like the pedals shifted?
Dakazman