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Convert Silverado DBW Pedal to DBC

As a continuation from building a throttle cable bracket.. It was time to install a compatible throttle pedal assembly.

Info

This post was originally published in 2018, and has been adopted to this static-site from wordpress. The build has since been retired.

The factory throttle pedal was designed for DBW (Drive by wire), and had no provisions for mounting or attaching a throttle cable. It was strictly intended to be used electronically.

I had planned on using the Holley EFI to utilize DBW.. but- I did not want to spend 1,000$ extra on the dominator vs hp efi just for this feature. I did also visit a junkyard to acquire a factory DBC pedal assembly- but, discovered the assembly would require disassembling most of the dash to remove from the Junkyard vehicle. So- I decided to modify my factory pedal to suit my needs!

Factory drive by wire pedal assembly. Here is my factory drive by wire pedal assembly.

Removing extra material. I started by removing a lot of the "Extra" material which was not required for my purposes.

Removing the DBW sensor. To remove the DBW sensor- I used a hammer. My other efforts of removing the sensor were not successful. The hammer was extremely successful.

Junkyard DBC pedal. While I was at the Junkyard- I did acquire a DBC pedal from a random car. Ignore the piece of metal hanging off my pedal.

Filling the empty space. After removal of the DBW sensor, a large hold was left. I used a piece of 16ga steel to fill in the empty space. Also note- I cut the "stop" off, and adjusted its position and angle to allow more pedal travel.

Lokar throttle cable installed. From the factory, there was a flat location on the firewall, which I assume was intended for DBC. I drilled a hole, and installed my new lokar throttle cable.

Another view. Another view.

Preparing to cut and weld. Preparing to cut and weld.

The next day…. (Ran out of daylight)

Cut apart junkyard pedal. I cut apart the junkyard pedal into the components required. I beveled the edges before welding to ensure good penetration.

After welding. After welding.

Adjusting angles. I had to mount the gas pedal many times and make adjustments before I was able to get the angles perfected.

Pedal travel adjusted. After many attempts- I was able to get everything lined up properly, with the correct amount of travel.

Finished assembly with spring. Here is my finished assembly after welding, grinding, and painting. Notice a spring was also added to return the pedal to an upright position.

Mounted and completed. Mounted and completed. The truck now has a functional gas pedal.