Economy Pedal Kit for 2 Wheel Brakes

OVERVIEW

When you''re building a dedicated off-road machine, whether it''s a rugged woods buggy or a classic sand rail, the interface between the driver and the machine is paramount. The Appletree Automotive Economy Pedal Kit for 2-Wheel Brakes provides a robust, hydraulic solution for those looking to move away from the often-clunky stock mechanical linkages. This assembly is designed to offer a clean, floor-mounted installation that simplifies your chassis plumbing while providing the tactile feedback necessary for precision driving. By utilizing a hydraulic clutch and a single master cylinder for the braking system, this kit eliminates the stretching and snapping of cables that frequently plague air-cooled Volkswagens in harsh environments. The integrated roller-style accelerator pedal ensures a smooth throttle response, allowing for finer control when navigating technical terrain or modulating power through the dunes.

While labeled as an "Economy" kit, this unit doesn''t compromise on the essential engineering required for reliable stopping power and clutch engagement. The kit features a 3/4-inch bore master cylinder for the brakes, which is the industry standard for providing the correct volume and pressure to a pair of rear wheel cylinders or disc brake calipers. On the clutch side, the 5/8-inch master cylinder provides a light yet firm pedal feel, making it easier to manage heavy-duty pressure plates without leg fatigue. The entire assembly is constructed with a focus on durability and ease of maintenance, featuring standard 1/8-inch NPT outlets that allow for easy adaptation to hard lines or braided stainless hoses. If you are looking to streamline your cockpit and upgrade to a modern hydraulic feel without the premium price tag of high-end racing units, this pedal kit is the definitive choice for your next air-cooled project.

FITMENT

This pedal kit is a universal-style assembly designed for custom off-road applications. It is most commonly used in the following vehicles:

• Sand Rails: All custom tube-frame chassis configurations.
• Dune Buggies: Fiberglass body buggies including Manx-style and Berrien frames.
• Baja Bugs: Custom floor-pan or tube-chassis race builds.
• Woods Buggies: Ideal for tight-clearance cockpits in trail-riding frames.
• Custom Trikes: Frequently used in VW-powered three-wheelers requiring floor-mount controls.
• Note: This kit is designed for 2-wheel braking systems only; it is not intended for 4-wheel brake applications without additional proportioning or master cylinder changes.

SPECS

• Brake Master Cylinder Bore: 3/4 Inch (Ideal for 2-wheel brake setups).
• Clutch Master Cylinder Bore: 5/8 Inch.
• Accelerator Type: Integrated Roller Pedal.
• Total Pedal Height: 9 Inches.
• Total Assembly Width: 11 1/4 Inches.
• Overall Length: 12 1/2 Inches.
• Mounting Bolt Pattern: 4 Inches x 2 3/8 Inches.
• Fluid Outlet Size: 1/8 Inch NPT.
• Master Cylinder Dimensions: 4 7/8 Inches Wide x 5 Inches High.
• Recommended Fluid: DOT 3 Brake Fluid ONLY.
• Construction: Heavy-duty steel mounting base with reinforced pedal arms.

PRO TIPS

1. Bench Bleed Before Installation

One of the most common mistakes builders make is installing the entire pedal assembly and plumbing the lines before bleeding the master cylinders. Because these cylinders sit at an angle, trapped air can be incredibly stubborn to remove once they are mounted in the vehicle. We strongly recommend "bench bleeding" both the 3/4-inch brake master and the 5/8-inch clutch master using a simple bypass kit. By cycling the pistons while the units are level on a workbench, you ensure that every bit of air is purged from the internal chambers. This simple step will save you hours of "spongy pedal" frustration and ensure that your first trip to the dunes has a firm, reliable pedal feel right out of the gate.

2. Adhere Strictly to DOT 3 Fluid Requirements

The seals within this economy pedal kit are specifically engineered for use with DOT 3 brake fluid. While it might be tempting to use DOT 5 silicone-based fluids or high-performance DOT 4 variants, doing so can lead to premature seal swelling or degradation in these specific master cylinders. DOT 3 fluid provides the necessary lubrication and viscosity for the internal plungers to operate smoothly without sticking. Additionally, always ensure your reservoirs are mounted higher than the master cylinders to maintain a constant gravity feed, preventing air from being sucked into the system during aggressive maneuvers or steep climbs.

3. Optimize Your Pushrod Alignment

When mounting this kit to your chassis, pay extremely close attention to the alignment of the pushrods entering the master cylinders. The pushrods must travel in a perfectly straight line into the cylinder bore. If the pedal assembly is mounted at an awkward angle or if the floorboard flexes, the pushrods will apply side-load pressure to the seals. Over time, this side-loading will cause the master cylinders to leak or, worse, cause the piston to gall the inside of the bore. We recommend reinforcing the mounting area of your floor pan or chassis with a 3/16-inch steel plate to ensure a rigid foundation that keeps your geometry true under heavy emergency braking loads.