Re: Upgraded Stock Brakes on a 1980 El Camino with Manual Br
Stroked383 said:
Can you elaborate on how you made the rod to go from the pedal to the master? I'm in the process of doing this swap and want to make a secure rod. I have one of your adapter plates btw.
Thanks
Cory
Cory,
I am not a machinist but this is the parts I initially used below and how I put together my linkage. I have since upgraded the rod end to a custom rod end designed my me. I designed my own because I wanted something that would not have the potential to fail and have a better fit on the pin (stud) with no slop.
I used:
1.25" long 1/2" daimeter industrial steel pin (stud)
Matching retention pin for the steel pin above (keeps the rod end from falling off the pin (stud)
5/16-24 RH spherical industrial rod end (high quality, not home depot stuff)
5/16-24 5.0" long grade 8 bolt (this will be modified into a master cylinder brake pedal pushrod)
5/16-24 grade 8 nut (this will lock the pushrod to the rod end and lock the length into place)
ATTENTION/NOTE: I used high quality industrial type material above for the rod end and the steel pin (stud). The stud and the rod end I bought online. The Home Depot/Lowes stuff is very low quality and
SHOULD NOT be used. These are your brakes used for stopping your vehicle. Failure of these braking components will cause loss of your braking system and could cause injury or death. Do this modificatin at your own risk.
IMPORTANT: Make sure you have something to retain the brake pushrod to the master cylinder. If you don't, this will cause a total loss of brakes. Make sure you retain the brake pedal pushrod to the brake pedal. If you don't, this will cause a total loss of brakes.
I mocked up everything on the bench by removing my brake pedal assembly from underneath the dash of the car. I used a press to install the 1.25" long 1/2" diameter pin (stud) into the top manual brake hole on the brake pedal making sure that the hole for the retention pin was not inline with the power brake pin (stud) below it. This is a press fit and the pin will not move once installed.
I next modified the 5/16-24 spherical rod end. I used a press and pressed out the spherical ball. The hole will be a little larger than the 1/2" pin (stud) after you press out the spherical ball, but it will work. I then test fit the rod end on the 1/2" pin (stud) that I pressed onto the brake pedal making sure it slid over it without too much slop.
I next bolted up the aluminum manual brake adapter plate to the brake pedal assembly on the bench starting with the two lower holes first. If you have a gasket,
DO NOT use the gasket during this proceedure. Next bolt your master cylinder to the aluminum manual brake adapter plate and brake pedal assembly.
Now we have to modify the length of the 5/16-24 grade bolt and also make it into a brake pedal pushrod. Screw the 5/16-24 grade 8 nut onto the 5/16-24 grade 8 bolt to where is ALMOST bottoms out on the bolt (do not tighten at the bottom, back it off of the bottom of the threads of the bolt so it is free to turn). Now screw the 5/16-24 grade 8 bolt onto the modified 5/16-24 rod end until it bottoms out (back it off slightly so it is loose and free to turn). Install onto the brake pedal pin (stud). Install the brake pedal switch into the brake pedal and screw it in only enough so it doesn't fall out (this will give you maximum brake pedal travel). Give the brake pedal switch a small tug to verify that it is securely threaded enough to hold. With the brake pedal against the brake light switch, swing the 5/16-24 grade 8 bolt up toward and against the bottom of the master cylinder. With a permanent marker, mark the bolt where it needs to be cut.
NOTE: If you are using a master cylinder with a deep pushrod retention hole, measure the depth of this hole and add it to the mark you placed on the 5/16-24 grade 8 bolt.
Once you determined the length you need, remove the pushrod assembly off the pedal and cut the bolt where you marked it. Once cut, reinstall onto pedal and test fit. If it is still to long, remove and trim a small portion off the end and refit. Once the correct length is found, round off the end ( I used an abrasive disc). Install the pushrod assembly back on the pedal, and adjust your pushrod out to where it barely touches the master cylinder piston.
If any one has questions about this install, please email me at:
[email protected]