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[Lil'John]

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[Prairie Swamp]

Will it be accurate enough is you shim the gasket or whatever the template is off the surface 1/8” or whatever. I’ve done this. If you’re worried about parallax error or tilting the punch put the punch in a drill press to at least get a scratch mark.

 

[ProjectsNMotion]

If I were you, I'd get some bolts that are the exact size of the holes in the pedal hanger, then center drill those bolts, then install those bolts with nuts on the pedal hanger, and use a center punch / awl / scribe, whatever, down through the bolts to transfer the marks

 

[ProjectsNMotion]

This would work but I think the pedal bracket holes are some odd ball size... the brake booster are 8mm and are undersized.

I've seen this version with the bolts ground down to points instead of drilling a hole down the middle.

I'm not sure how thick the flange on the pedal hanger is, but if there's a bit of thickness there and the holes aren't an exact size, you can use a flat socket cap screw, which, because of the tapered head, automatically centers in the hole when tightening.

 

[WarDamnEagle]

1mm to 13mm Transfer Punch Set

www.shars.com

These work on fairly thin material but the point might still be too long??

Would probably work with some gasket material as a spacer.

 

[mrsleeve]

is the pedal hanger still in the truck???? If not why not use the old grade school trick of putting a sheet of paper and then scrub a pencil (or dirty fingers) over the paper to transfer the outline of the part and all the holes and other features to the paper.... Then use that as your lay out template to your new material....

 

[ntsqd]

Helps to have a lathe, but the way that I do this sort of thing is to turn a short remnant of aluminum to have a step that tightly fits the hole. Then drill or bore it to the size of one of you transfer punches. If you make the step not quite as wide as the material is thick then the 'flange' around the step also aids in keeping it perpendicular.
HTH