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Brake handle replacement idea?

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Old Sep 15, 2024 | 12:53 PM
  #16  
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Originally Posted by 654x4
Has anyone used the aluminum one linked above? They show it fits the Mustang, just no mention of the F series pickups
I have not used it. The offset one from DC lists these vehicles for fit... so by that, I'd say it fits... Check the crossover with that Scott Drake part # which looks to be for a 65.


 
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Old Sep 16, 2024 | 12:19 PM
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The problem with using the car offset handle is the hole for the pin to connect to the sector shaft is on the inside toward the handle grab. With the trucks the retaining pin came in from the bottom. So, to make the car handle work with the truck sector shaft you have to drill the handle in a spot either on top or bottom. Or mount the handle so it points down - Can't point up since it would hit the dash and with it pointing down it can be in the way of your shin if you have a clutch. Drilling the plastic ones weakens them and makes them more susceptible to breaking. The billet one probably would hold up better but sort of a shame to drill a new billet one. They need to make a truck billet one.
 
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Old Sep 18, 2024 | 12:24 PM
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It looks like my options here are to buy a NOS Mustang handle and mount it upside down, or buy the Scott Drake aluminum and drill it out. Any ideas of which would be strongest?
 
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Old Sep 18, 2024 | 12:27 PM
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Originally Posted by 654x4
It looks like my options here are to buy a NOS Mustang handle and mount it upside down, or buy the Scott Drake aluminum and drill it out. Any ideas of which would be strongest?
I would think the aluminum handle would be stronger.... I would probably drill the steel rod for the car mounting instead of the handle. Just my $.02.
 
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Old Sep 18, 2024 | 01:52 PM
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You think I just hit the steel rod with a grinder or punch to make a flat spot and start with a small bit and get bigger? Looks like a PITA with a 18v drill
 
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Old Sep 18, 2024 | 02:31 PM
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Originally Posted by 654x4
You think I just hit the steel rod with a grinder or punch to make a flat spot and start with a small bit and get bigger? Looks like a PITA with a 18v drill
Yeah, Just a nick with the grinder would work. Put it a vise if you have it out of the truck and possibly invest in a high quality bit to drill it. From the image of the aluminum handle the pin may be smaller than the truck style... Not sure on that. Wait until you get it in hand to drill. Good luck.
 
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Old Sep 18, 2024 | 02:52 PM
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Ill have to do it while installed in the truck. Ill update the post if/when I get it installed
 
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Old Sep 18, 2024 | 02:57 PM
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The aluminum handle says it comes with a new drive pin and an Allen head set screw.

The trucks used the same pin as the cars but some variance measuring that outside diameter. Plus, cars listed in decimal and trucks fractional. Consistency is highly overrated...

Might be able to drill it but a drill press and good machine vice would probably help if you knew anyone with one. A little accuracy might go a long way in this case.

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Old Sep 18, 2024 | 03:01 PM
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I think its worth pulling it from the truck to do the drilling in a vise... Its just a couple bolts at the firewall and the dash... I just restored one from my 64.


 
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Old Sep 19, 2024 | 01:50 AM
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You may be able to use the existing hole in the handle to pilot the drill bit. If there is a set screw as well, use that to position and hold the handle, then use the pin hole to position the drill to create a good dimple. Then remove the handle and finish drilling the steel. The 5/32 spring pin should fit well in a hole up to ,160". So with some care not to screw up the aluminum or steel, you should be ok
If the pin doesn't want to go through both, then line them up and chase the hole as an assembly.
 
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Old Sep 25, 2024 | 06:22 PM
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Just an update. I got the aluminum handle. It has set screws at the 3 and 9 O'clock position. My shaft has holes at the 12 and 6 O'clock position. I attempted to drill the shaft while attached to the vehicle. That did not work out well. IIRC taking the cable off of the handle is a royal PITA, I might have a local shop fab up a metal piece with holes at 12 and 6. I attached this new one so I can at least drive it while I figure something out. I wanted to post these photos in case it helps someone down the road.




 
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Old Sep 25, 2024 | 07:32 PM
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Can you install it in the desired orientation using just one set screw, and use the opposite hole to guide a drill. Then flip it and do the same?
 
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Old Sep 25, 2024 | 07:38 PM
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Originally Posted by 66F250_4x4
Can you install it in the desired orientation using just one set screw, and use the opposite hole to guide a drill. Then flip it and do the same?
I think that would risk screwing up the threads... But maybe using a 1/2" pipe drilled as a guide would work... Good idea
 
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Old Sep 25, 2024 | 07:42 PM
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It would probably be a lot easier to drill and tap the handle for set screws instead of drilling the rod. Sucks they don't put the set screws in the right place.
 
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Old Sep 25, 2024 | 07:52 PM
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I just can't get the drill at 90 degrees. I think it would be easier to drill the handle now that you mention it. Maybe even drill it out without threads and use a bolt to hold it on instead of set screws.
 
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