Welcome back to Episode 6 of the 1967 International Loadstar van chassis swap! In this chapter, we dive deep into the custom fabrication work needed to finalize the pedal setup, including precision modifications to the brake and gas pedal assemblies. These crucial details may not look flashy, but they make or break the driving experience in a custom build.
Reworking the Brake Pedal
The first order of business was addressing the awkward angle of the brake pedal. Sam heated the arm, used a press for alignment, and then trimmed the length to fit the cabin layout more comfortably. To lock in the correct shape, he V-notched the arm, bent it to the correct angle, and TIG welded it back together. For added strength, a diamond-shaped reinforcement plate was welded to the side.
After some test fitting inside the cab, it became clear that the original bracket was still interfering with Sam’s boot. The pedal assembly was relocated upward by 1.5 inches. This required new holes to be drilled in the firewall—and yes, some extra holes had to be welded shut after repositioning, but that’s just part of the job when you’re building from scratch.
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Tackling the Gas Pedal
The gas pedal presented more of a challenge. The stock van pedal was never designed to fit the narrowed firewall and floor geometry of the Loadstar cab. Sam brainstormed a custom mounting solution, choosing to bolt in the pedal unit and fabricate a custom foot lever from scratch.
Using a mix of dowel rods, hot glue, and hands-on testing, he mocked up the ideal foot position. From there, he transferred the shape onto sheet metal and built a multi-piece steel bracket that sandwiches the foot lever together with adhesive and TIG welds. The pedal needed a twist to align properly with the driver’s foot position, and once installed, the action felt just right.
Final Fitment & Function
After plenty of templating, trimming, and welding, both pedals were in. The final brake pedal sits cleanly in its own space, while the throttle pedal now has smooth, responsive travel without interfering with anything. The results are not only functional—they look like they belong.
The process may seem like overkill to some, but the custom fit and finish of the foot controls ensure a comfortable, confident driving experience. As Sam says, “We could’ve done something easier, but we couldn’t have made it look better.”
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What’s Next?
With a functional pedal setup and steering column locked in place, the Loadstar is inching closer to first drive status. Next up: finishing the brake lines, installing the radiator, and completing final hookups. The vision for a slammed, old-school stake bed farm truck on modern underpinnings is coming to life.
Sam also hints at returning to the Audi widebody project with new machined parts and a fresh redesign of the rear bumper. Big updates are on the way for both builds!
Follow the Build
If you’ve been enjoying the Loadstar van chassis swap series, now’s the time to subscribe and follow along on YouTube and Instagram. Your likes, comments, and shares go a long way in supporting the StealthBuilt channel—and there’s more custom fabrication coming your way every week.
Stay tuned for Episode 7, where we wrap up the brakes, cooling, and prep this beast for its first real shakedown.
