Ok, got a bit more done tonight but work is seriously getting in the way of 101 time!
One of the things I thought I'd look at when doing the brakes is the brake booster - I fitted a D1 dual diaphragm booster a couple of years back and it transformed how the vehicle stopped, but it isn't without its issues. Mounting it to the pedal assembly is pretty easy but as it is much thicker, it pushes the master cylinder back quite a bit - to the point that you have to take just a whisker off the back of it to clear the steering column bracket - no huge issue, but something that bugged me a bit. Also, I found getting the speedo cable to fit properly and work was nearly impossible due to the extra width of the unit, although I know others that have had no issue with this. Lastly the D1 booster has quite a wide opening where the MC mounts which necessitates slotting the MC holes quite a bit - actually slotting them to the outside - again, no real issue as I made up some large thick tabs that directed the force of the mounting nuts back towards the centre of the MC.
Anyhow, I'm having another crack this time and bought an 8" aftermarket dual diaphragm booster to trial. If it doesn't work how I want it, I'll go back to the D1 booster. FOr a start it has 4 mounting bolts and bolts up to the pedal plate easily and will be more secure, particularly when I make up some plates to go behind it. Secondly it is 1/2" thinner so it's bough the MC back so it doesn't foul the steering column bracket. It is also a lot narrower so the speedo cable would fit much better although I've since converted to a GPS speedo so this is not so much of an issue for me. I've installed a 7/8" bore MC so hoping this will make up for the assistance the lack of area on this booster gives me compared to the D1 unit. Pedal travel is still unknown though, so may have to go back to a 1" bore, but time will tell.
So a few pics.
Mounted up on the bench.
IMG_0560 by Gavin Gregory, on Flickr
Temporarily fitted to check clearances - it fits very well, better than the D1 unit.
IMG_0561 by Gavin Gregory, on Flickr
A close up showing the fit on the booster - the holes were filed out around 1mm each side to get this to fit, so much happier than the D1 setup.
IMG_0562 by Gavin Gregory, on Flickr
And with the steering bracket fitted - everything clears without issue.
IMG_0563 by Gavin Gregory, on Flickr
So it FITS better, but it's not all beer and skittles (mmmm, beer...). The input to the booster needs a new bit making - not a huge issue apart from the thread size on the rod which I cannot work out - it is a fine thread - not UNF or Metric, so not sure - my local bolt supplier couldn't work it out either, so a bit stumped on that one and need to do some more research. The output rod is not adjustable so I also need to make up a rod extension for this (but you have to do that with the D1 booster too).
Lastly its performance is currently unknown, so until I get everything finished I'm not going to know if it is good enough. That could be a while too as I've now got all the steering out of the vehicle, so road testing won't happen until the PS conversion is complete - which will be a few weeks I think.
Anyhow, will get the other side of the discs on, finish off the upfit of this booster and get it all back together so I can crack on with the steering. Hopefully have all this complete by the end of the coming weekend.
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