02a swap, homemade cable clutch actuator

[b1rdjx88]

    I'm thinking of putting an 02a in my car to replace a tired 020 while I have the engine out anyways.  

    I already have the 02a and all the hardware I need, but I think the clutch hydraulic components are shot, and I don't have a hydraulic pedal cluster for my car.  I've been  thinking I could fabricate my own cable clutch slave mechanism, and build it to use the stock mk3 clutch cable already in the car.  Thikning I'll get an oilite bushing and pin for the main pivot, grab the clutch pushrod from the hydraulic slave, and fab up a sturdy bracket and lever mechanism around those parts.  The tricky part would be getting the geometry right with the right lever lengths to get good pedal feel and a clutch engagement point in the right part of pedal travel.  I'm thinking I will need to build a few different iterations, making adjustments until I get it dialed in.

    If anyone could give me the dimensions of the eurovan cable actuator normally used for this conversion, that would give me a good place to start.  Specifically I'm looking for the distance from the main pivot to the cable pull point, and distance from main pivot to pushrod attachment point.  Or better yet, the total actuator pin displacement through full pedal travel, and the total cable pull through the same travel.        

    Someone built a similar device here: http://forums.vwvortex.com/zerothread?id=4527556
 

[jtanguay]

you know, i've been contemplating a system that get rid of all that nasty hydraulic junk. its called electro-magnetic 

you'll need to install a plate to the clutch actuator rod (some modification necessary to the slave cylinder obviously) and get a big enough coil to be able to move with about 20-30 lbs of force. then what you need is to buy one of those PWM circuits off ebay. get a low amperage one. a little modification will be necessary to splice in a better type of linear potentiometer. i think the potentiometer would be really cool right on the shifter knob.  that is the secret to how to get the magnetic actuation to act smooth and not like an on/off switch.

[TurboJ]

Look at a Passat 1.6 gasser MY '88-'94. They have a 02A transmission with a cable clutch. Maybe you could use those parts.