
Here's the old power booster,
about to be pulled out. This is going to give me some much
needed room to access the #5 and #7 plugs, not to mention improve the
braking.
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Well, this is what it looks
like with the old booster removed. If you notice, the almost oval
shape of the cutout from the factory to accommodate the installation of
the manual brake master cylinder in the top 2 bolt
holes. |
This is the gasket that was
between the power booster and firewall. I used this as a template to
fabricate a block-off plate to cover the large hole left by the removal of
the power brake booster. |
Here's the block-off plate I
fabbed from 1/8" aluminum plate. It's not pretty, but it
works. |
Click here to get a CAD mechanical drawing template of the
block-off plate in PDF format |
Here you see that I have cut
out the insulation in the top of the hole in the firewall.
You'll see the color my car was painted from the factory where the gasket
was located. Yep, it was brown.
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Here's my grungy old power
booster and master cylinder. It looked much better from the top,
because it was painted on the top side.... If you look, you
can see that it was obviously a junk yard piece because it has the
infamous yellow parts marker writing on it.
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Goodbye vacuum canister!
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Here's what Master Power sent
me. A manual master cylinder, adjustable pushrod with clevis
fitting, and rubber boot.
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This picture shows why the
Master Power kit is the easiest and SAFEST way to go. If you will
notice from this shot, the pushrod slides about 1.5" into the master
cylinder. It is drilled out large enough for the rod to fit inside of
the pushrod seat. There is NO WAY it can fall out.
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Here's a shot of the pushrod
seat, so you can see what I am talking about. The pushrod slides
about 1.5" into the machined seat.
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This shows how far it fits
into the master cylinder.
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This is a shot of the new MP
manual brake master cylinder bolted to the firewall/adapter
plate.
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This is what it looks like
from the side.
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Here's a shot from under the
dash of the pedal assy. and the new master cylinder rubber boot sticking
out. It is in a direct line with the top hole in the pedal
arm.
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Same as previous picture,
just a different angle. Man, it's not easy laying upside down
taking pictures under the dash!
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The pushrod in the MP kit is
WAY too long. It has to be cut. To determine the length it
needed to be, I got a piece of clothes hanger and inserted it into the
master cylinder and marked it where it intersects the center of the hole
on the pedal arm. The rod is threaded on the other end to allow
final adjustment of length. Unfortunately, my metal saw blade broke
before I finished cutting the HARDENED (and I do mean hardened!)
rod. I've got new saw blades, so I should have everything buttoned
up soon. MORE TO COME!
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