Pedal conversion kit problem

[Bbllaaxx27]

So since I've been delivering mail I've had a conversion pedal kit on the passenger side. It gets the job done. But the cables that connect the main pedals to the passenger side pedals, break. It's happened about 5 times now for the brakes and 3 times for the gas. Far to many and it is utterly terrifying every single time. Thankfully I have been able to coast to a stop or wasn't going so fast that serious damage was done when crashing into a tree. With that being said, my question is, why does this keep happening and how do I stop it from happening? I'm too short legged and armed to straddle so that isn't an option for me. Has anyone else had this problem? Desperately needing advice and tips on this. Thank you so much!! (I bought the conversion kit online at A&J Mobility)

 

[DaveKelln]

You likely have the FAT system. The cables are supposed to be replaced every year. You could try using a heavier gauge cable. Take your broken cable to home Depot and compare it to the stuff they sell by the foot. It's a lot cheaper than buying the FAT cables, and more durable. They also have loops and stops that you can either crimp or bolt on to the raw ends of cable. Should work with your existing cable housings.

 

[DaveKelln]

Another quick thought. Make sure that everything is properly installed. The cables will eventually break regardless (which is why they recommend new ones every year), but you should make sure the cables move properly on the pulleys- nothing is rubbing on the cable s.

 

[jaymacgthree]

I have had the FAT system from the Dual Brake website for 4 years and never had a cable break. Look closely at the pulleys and make sure the cable isn't slipping off and getting caught alongside the pulley mount. That can happen because most people still drive from the left side of the vehicle when not delivering mail and their isn't enough tension on the cable from the remote pedals when you depress the factory peddles. The slack allows it to come off the pulley and the wear eventually breaks it. That happened twice to a colleague of mine who always contacted me because she knew I kept spare cables since I'm the type to always have a contingency plan.

 

[DaveKelln]

That can happen because most people still drive from the left side of the vehicle when not delivering mail and their isn't enough tension on the cable from the remote pedals when you depress the factory peddles.

Good point! As soon as I arrived back at the office I would unhook the accelerator cable, pop the brake pedal off, and drive home sitting on the left side of the car.

 

[The Happy Friar]

I have the Pedal Pro's kit and it doesn't have cables from side to side, it has the sables go under the driver, around the back, up the passenger, to the new pedals. I've had them since 2018 and the only problems I've had is when putting it in a new vehicle I'd sometimes need to fabricate some new parts to get the gas pedal to work properly and add/remove some steel from the floor places. The cables have help up great. It's more expensive though. I also don't disconnect my gas pedal normally unless we're taking the mail vehicle farther then a couple miles.

 

[DaveKelln]

I have the Pedal Pro's kit and it doesn't have cables from side to side, it has the sables go under the driver, around the back, up the passenger, to the new pedals. I've had them since 2018 and the only problems I've had is when putting it in a new vehicle I'd sometimes need to fabricate some new parts to get the gas pedal to work properly and add/remove some steel from the floor places. The cables have help up great. It's more expensive though. I also don't disconnect my gas pedal normally unless we're taking the mail vehicle farther then a couple miles.

I am pretty sure that the pedal pro kit is from this company:

Company Overview - Shanghai Z-Show Industries Co., Ltd.

Shanghai Z-Show Industries Co., Ltd. Products:dual brake,double brake in passenger side,driving training car brake,instruction car brake,hand controls for disabled people

zshow.en.alibaba.com

I think they just have a bunch of them drop-shipped and they rebadge them and sell them.
That said, I have a coworker who has it and it works fine for her.

 

[DaveKelln]

So since I've been delivering mail I've had a conversion pedal kit on the passenger side. It gets the job done. But the cables that connect the main pedals to the passenger side pedals, break. It's happened about 5 times now for the brakes and 3 times for the gas. Far to many and it is utterly terrifying every single time. Thankfully I have been able to coast to a stop or wasn't going so fast that serious damage was done when crashing into a tree. With that being said, my question is, why does this keep happening and how do I stop it from happening? I'm too short legged and armed to straddle so that isn't an option for me. Has anyone else had this problem? Desperately needing advice and tips on this. Thank you so much!! (I bought the conversion kit online at A&J Mobility)

And you can also buy the FAT system/components here.

 

[The Happy Friar]

I am pretty sure that the pedal pro kit is from this company:

Company Overview - Shanghai Z-Show Industries Co., Ltd.

Shanghai Z-Show Industries Co., Ltd. Products:dual brake,double brake in passenger side,driving training car brake,instruction car brake,hand controls for disabled people

zshow.en.alibaba.com

I think they just have a bunch of them drop-shipped and they rebadge them and sell them.
That said, I have a coworker who has it and it works fine for her.

no..... that's nothing like what they sell. It's hand made by the guy(s?) who work at the shop.

Right Hand Drive Pedal Conversion for Rural Mail Delivery | PEDAL PROS

PEDAL PROS right hand drive (RHD) pedal kits for rural postal delivery.

www.pedal-pros.com

 

[Morty]

@Bbllaaxx27

I've run this system for 13 years. My 1st install, I had failures often. My problem was that my pulleys weren't tightly secured and were not perfectly/or close to perfectly aligned with the pedal movement.

When pressing on the brake, the cable should go straight back, not rubbing at an angle on the pulley. The cable should also be fairly tight. My cables would fray, then break because they went into the pulley at a slight angle and the pulley wasn't secure and immovable. I kept spare cables in the car. I got them at a hardware store, they cut to length and pressed on the hoop fittings.

My subsequent vehicles, I made sure to securely fasten the pulleys solid and to get them aligned perfectly. After that, they never frayed or broke. Over 100,000 miles on the same cable. I still use the same kit I bought 13 years ago. I replace the cables and housing with each vehicle it goes in.

 

[Havenowgone]

So since I've been delivering mail I've had a conversion pedal kit on the passenger side. It gets the job done. But the cables that connect the main pedals to the passenger side pedals, break. It's happened about 5 times now for the brakes and 3 times for the gas. Far to many and it is utterly terrifying every single time. Thankfully I have been able to coast to a stop or wasn't going so fast that serious damage was done when crashing into a tree. With that being said, my question is, why does this keep happening and how do I stop it from happening? I'm too short legged and armed to straddle so that isn't an option for me. Has anyone else had this problem? Desperately needing advice and tips on this. Thank you so much!! (I bought the conversion kit online at A&J Mobility)

I always went with the dual controls that used a steel bar and leverage for the gas and brake. There was nothing to break. I didn't trust cables because of their tendency to break. This company still installs them and they install the cables also. It depends on your type of vehicle. Another thought is true right hand drive and I know there are some vehicles still made and available to rurals. Here is the link for the company that installs the steel bar dual controls. Maybe there are cable gas and brake kits that are reliable, idk. Check out the union magazine. Anything that was not 100% safe was a dealbreaker for me. Cables that could break are not only a possible hazard to yourself, they are a possible hazard to the public. I don't know why the USPS hasn't put RHD vehicles on every route in the USA, especially when they always preach safety first. Good Luck.

Morgan Dual Controls LLC (Heber Springs, AR)

Custom Installation Only WE DO NOT OFFER KITS

morgandualcontrols.com

 

[The Happy Friar]

cables with a sharp angle will brake much faster then one not. When I got my pedals I needed something I could install and switch between vehicles for when mine died. I see Morgan Duel controls also does the cables direct from driver to passenger.

Overall my cables haven't worried me. They're pretty thick and I haven't had issues with them. I've replaced the throttle cable in my last two mail vehicles though, so I know they don't last forever. Each vehicle was 20+ years old when I had to replace the throttle cable.

 

[DaveKelln]

no..... that's nothing like what they sell. It's hand made by the guy(s?) who work at the shop.

Right Hand Drive Pedal Conversion for Rural Mail Delivery | PEDAL PROS

PEDAL PROS right hand drive (RHD) pedal kits for rural postal delivery.

www.pedal-pros.com

You are right - It's safe drive that I was thinking of.

 

[Joe Reeser]

So since I've been delivering mail I've had a conversion pedal kit on the passenger side. It gets the job done. But the cables that connect the main pedals to the passenger side pedals, break. It's happened about 5 times now for the brakes and 3 times for the gas. Far to many and it is utterly terrifying every single time. Thankfully I have been able to coast to a stop or wasn't going so fast that serious damage was done when crashing into a tree. With that being said, my question is, why does this keep happening and how do I stop it from happening? I'm too short legged and armed to straddle so that isn't an option for me. Has anyone else had this problem? Desperately needing advice and tips on this. Thank you so much!! (I bought the conversion kit online at A&J Mobility)

I don't know anything about these installations but I have worked on aircraft cable systems. I went to A&J Mobility's website but there's precious little information about their system. Their 'installation time-lapse' video is next to worthless. With all of that said, I may have a suggestion anyway.

Your cable is likely a 7x7 cable, or wire rope as we used to call it. If you can find the same size diameter cable (or possibly one just slightly larger) in the 7x19 style, the cable will be stronger and more flexible. A 7x7 cable is built from 7 strands, and each strand has 7 wires (49 wires in total). The 7x19 variant includes 7 strands with 19 wires each, giving the rope 133 wires. I would also try to get it in stainless steel if possible.

As Morty already mentioned, it is also imperative that the pulleys be aligned as perfectly as possible. I don't know if this will help but depending on what type of cable they provide in their kit, it may.