Chassis Modification Question

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    This is a question for those who have done the chassis mod (pedal cluster and shift lever) on their TDs with the VW chassis. A little long but bear with me please.

    All the manuals say to cut and/or drill new holes in the tunnel. I was wondering if the shift lever area and the pedal cluster area of the tunnel can be cut out and repositioned where needed on the tunnel and move the tunnel metal to where those pieces were. That would make less extra holes in the tunnel while keeping the strength of the tunnel. Has anyone done this?

    Allen Caron
    VW based 53MGTD - "MoneyPenny"
    "If one thing matters, everything matters" - from the book The Shack

    Paul Mossberg


    You will be doing more major reconstruction, with more potential for weakening the tunnel, then by simply cutting new holes.

    More work, LOTSmore work, with a larger potential downside.

    I recommend sticking with the tried and true.

    I cannot explain the physics. But I learned a long time ago from an old-time carpenter, you can drill a round hole in a two-by-four (or any post or beam for that matter) without weakening it.

    Same thing applies here. You drill two large holes (one each for pedal cluster and shift) and four small ones for the bolts. It does not weaken the tunnel.

    If you want, you can weld plates to close up the old holes. But it is not necessary.


    Paul Mossberg
    Former Owner of a 1981 Classic Roadsters Ltd. Duchess (VW)
    2005 Intermeccanica Roadster

    If you own a TDr and are not in the Registry, please go to and register (you need to copy and paste the link)

    Mark Konrad


    Allen you might call a Ron @ Sunshine Garage in Sarasota Florida.  He moved my pedal cluster and all he works on are VW’s.  He could tell you I am sure.  His no. is 1-941-365-6684.  Tell him I suggested you call him, his been a great guy to deal with.

    Happy New Year, and hope to see you again in 2012.

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