PLEASE READ: Malibu Racing Lives!!

Manual brakes+++UPDATE++w/more pics

Questions, answers, tips and tech on wheels, tires and brake issues

Moderator: Moderators

Post Reply
User avatar
Wile E
Dragway Regular
Posts: 1075
Joined: Mon Aug 11, 2003 5:59 pm
Location: Central WISC

Manual brakes+++UPDATE++w/more pics

Post by Wile E » Sun Jan 15, 2012 7:02 pm

I've been watching the manual brake post here and on other sites very closely because I'm doing the same thing. I've seen alot of the same questions keep popping up (including some by me) and I thought some pictures may help clarify things. I'm not a brake guru. I hoped to have this finished up this weekend, but been called into work a few times. So here's what I've got so far.....Moderaters..this may belong in the technical section, please move it if necessary.
Here's the brake peddle from my parts car with power brakes, the upper hole (above the pushrod stud) is the hole thats needed for the manual brake pushrod to have the proper leverage.
Image
Here's my brake peddle with the new stud pressed in (I added a bit of loctite for peace of mind) The old power brake stud could be removed, I left it.
Image

Opening left in firewall after removing booster
Image
Here is the adapter plate I had intended to use from a manual brake s10. Notice how the mounting holes are distorted from the bolt torque.
Image
Instead....I'm using this aluminum adapter plate. Notice it has a integeral cup to retain the pushrod. More on that later...
Image
The opening in the firewall need some minor trimming when a pushrod retaining cup is used, not much, took about 2-3 minutes to open up the upper portion of the opening about 1/8", I test fitted the s10 type also, that cup size is larger and would have required even more trimming.
Image
Image
Thats it for now. Next weekend I hope to finish up and show some pictures of the custom pushrod and Manual master bolted up. Special thanks to Malibudave1978. He's helped me get this project headed in the right direction. The guy knows his stuff!!
.
Last edited by Wile E on Sun Jan 22, 2012 9:07 pm, edited 2 times in total.
'79 Malibu work in progress. Body-off, Mini-tubbed, Notched. 406 Hyd roller/2004r, 8.5" GN rear, Non A/C car, manual brakes/manual steering, tucked bumpers. Owned since 1983. First car![/color]

User avatar
guysmontess
Frequent Racer
Posts: 344
Joined: Wed Jan 23, 2008 1:16 pm
Location: Nova Scotia Canada
Contact:

Re: Manual brakes with pictures

Post by guysmontess » Tue Jan 17, 2012 7:22 pm

Thanks for posting those pictures Wile E,I have also been following the posts on this subject.If it works as well as I hope it does,I may be doing the same thing,so keep the pictures & info coming !!!
Guy
'86 Monte SS,513 Big Block,AFR Rectangular Port Heads,UDHarold/Bullet Custom Grind Solid Roller,.706,255/263 @ 0.050,110 LSA,Weiand Stealth,Mighty Demon 800 DP,Hooker 2 inch Headers,Jesel Shaft Rockers,One Peice Trend Pushrods,Doug Nash 4+1 5 Speed,Hurst Inline Shifter,Ford 9 Inch

User avatar
rocketolds400
Amateur Racer
Posts: 111
Joined: Sat May 12, 2007 11:58 am
Location: Columbus, OH

Re: Manual brakes with pictures

Post by rocketolds400 » Thu Jan 19, 2012 1:42 pm

Thanks for taking the time to do a write-up! I'll be doing a conversion soon, but haven't decided on which route to take... :-k
BBO Power!

User avatar
slimbo
Moderator
Posts: 4221
Joined: Mon May 21, 2007 2:08 am
Contact:

Re: Manual brakes with pictures

Post by slimbo » Fri Jan 20, 2012 1:28 am

that upper hole yields a 5.5:1 ratio. depending on the master it is correct. for a 1 1/8 strange master a 6.5:1 is needed but for a 1.032 it is correct.
pump gas,3880 pound,9.43@141.8 1.24 60 foot, not your grandmas gp
2012 hot rod magazine drag week,3rd place small block power adder
You'd give it all up for what's there for the taking
Whatever it takes to keep your hands from shaking
The same things you're thinking might make you feel better
The same things that probably got you here

User avatar
slimbo
Moderator
Posts: 4221
Joined: Mon May 21, 2007 2:08 am
Contact:

Re: Manual brakes with pictures

Post by slimbo » Fri Jan 20, 2012 1:31 am

Image

heres the bracket my buddy made me that holds a strange 1.032 master at the right hieght to line up with the upper pedal hole...works great
pump gas,3880 pound,9.43@141.8 1.24 60 foot, not your grandmas gp
2012 hot rod magazine drag week,3rd place small block power adder
You'd give it all up for what's there for the taking
Whatever it takes to keep your hands from shaking
The same things you're thinking might make you feel better
The same things that probably got you here

User avatar
jacobgiles
Weekend Racer
Posts: 68
Joined: Wed Jun 27, 2007 6:27 pm
Location: Atoka TN

Re: Manual brakes with pictures

Post by jacobgiles » Fri Jan 20, 2012 3:06 pm

wile E,

did you fab or purchase the adapter plate?

which master are you going to use?

thanks...

User avatar
Wile E
Dragway Regular
Posts: 1075
Joined: Mon Aug 11, 2003 5:59 pm
Location: Central WISC

Re: Manual brakes with pictures

Post by Wile E » Fri Jan 20, 2012 5:39 pm

slimbo5, Thats beautiful!
jacobgiles, Malibudave1978 made the plate along with the adjustable pushrod I'll be picturing this weekend. I'm using
a new Raybestos 7/8" master cylinder part #39166
I'll be posting some more pics of the master cylinder and pushrod setup hopefully this weekend if I get time to work on it.
Nothing really exotic here, no 6 piston calipers or big inch rotors. Keeping it simple and within my budget.
'79 Malibu work in progress. Body-off, Mini-tubbed, Notched. 406 Hyd roller/2004r, 8.5" GN rear, Non A/C car, manual brakes/manual steering, tucked bumpers. Owned since 1983. First car![/color]

User avatar
Wile E
Dragway Regular
Posts: 1075
Joined: Mon Aug 11, 2003 5:59 pm
Location: Central WISC

Re: Manual brakes+++UPDATE++w/more pics

Post by Wile E » Sun Jan 22, 2012 9:05 pm

So here is the adjustable pushrod I'm using attached to the brake pedal, the longer pushrod is from the s10 set-up, but it would need to be shortend alot to work.
Image
Here's the factory pushrod still attached to the booster. The factory one is held captive within the booster and when the other end is attached to the brake pedal, it's a pretty solid and safe set-up that will not fall apart, when using a s-10 manual plate and cup, or one like I've shown with an attached cup, the push rod will not have an opportunity to lose contact with the master cylinder, without some type of pushrod retention, the pushrod could potentially lose contact if the pedal is over-extended. I understand some of the other custom set-ups also accomadate pushrod retention.
Image
Here's what the retention cup looks like from the interior side without the pedal assembly. (rubber boot not shown).
Image
Here's another veiw with the pedal/pushrod and boost installed. I used a original s10 boot, however it's a bit too long and not in the best shape, I may look for something that fits a little better. Also, notice the hole above the brake light switch, I believe it's for factory cruise control, It's not likely the push rod will fall away from the master with the retention cup, however
I plan on putting a bolt thru that hole and adjusting it to keep the pedal from over-extending (backwards) and having the pushrod fall out of the hole.
Image
Here's a pic from the firewall side.
Image
The kit I used came with some really nice detailed instructions, here's another picture of the parts I used (some nice stainless steel hardware was included shown in the firewall pic) thats the s10 set-up I had originally planned on using pictured next to the nice stuff.
Image
It will be a while before I get a chance to try all this out, calipers and brakes lines are on a LONG list of to do things.
'79 Malibu work in progress. Body-off, Mini-tubbed, Notched. 406 Hyd roller/2004r, 8.5" GN rear, Non A/C car, manual brakes/manual steering, tucked bumpers. Owned since 1983. First car![/color]

User avatar
t5montecarlo
MalibuRacing Junkie
Posts: 4377
Joined: Sun Oct 21, 2007 8:07 am
Location: Lederach
Contact:

Re: Manual brakes+++UPDATE++w/more pics

Post by t5montecarlo » Sun Jan 22, 2012 9:30 pm

Yes, the upper hole is for the cruise control vacuum switch.

malibudave1978
Amateur Racer
Posts: 226
Joined: Tue Jun 08, 2004 1:06 pm
Location: Houston, TX

Re: Manual brakes+++UPDATE++w/more pics

Post by malibudave1978 » Mon Jan 23, 2012 11:30 am

For the most pedal travel and to make sure that the pushrod does not fall out of the back of the retention cup:

1. Disconnect the brake light connector from the brake light switch.
2. Unscrew the brake pedal switch from the brake pedal assembly.
3. Pull the brake pedal back toward the driver’s seat until it resting against where the brake light switch screws into the brake pedal assembly.
4. If the pushrod falls out the back of the cup, adjust the pushrod to a longer setting until the pushrod does not fall out the back of the retention cup. It just needs to be long enough not to fall out of the back of the retention cup.
5. Tighten the locking nut on the adjustable pushrod.
6. Screw the brake pedal switch back into the brake pedal assembly until the pushrod assembly barely touches the piston in the master cylinder. You DO NOT want any preload on the master cylinder piston. This may cause the brake pads or shoes to drag.
7. Connect the brake light connector back on the brake light switch.
David Schultz
MalibuDave
http://www.manualbrakes.com" onclick="window.open(this.href);return false;
https://www.facebook.com/manualbrakesco ... 512373024/

User avatar
Wile E
Dragway Regular
Posts: 1075
Joined: Mon Aug 11, 2003 5:59 pm
Location: Central WISC

Re: Manual brakes+++UPDATE++w/more pics

Post by Wile E » Wed Apr 18, 2012 4:13 pm

I know this is an old post, but I finally got a reply from Wilwood on the whole "low drag" issue for their iron metric replacement caliper.
These are what I was thinking of using:
http://www.ebay.com/itm/WILWOOD-120-892 ... es&vxp=mtr
Here's their reply:
"Thank you for the inquiry with Wilwood Disc Brakes. All Wilwood calipers are build with our square o-rings in the piston bore. The 120-8924 is not considered a "low-drag" caliper."
Regards,
Wilwood Disc Brakes
'79 Malibu work in progress. Body-off, Mini-tubbed, Notched. 406 Hyd roller/2004r, 8.5" GN rear, Non A/C car, manual brakes/manual steering, tucked bumpers. Owned since 1983. First car![/color]

Post Reply