pushrods and yet another Hydroboost (my install)

Mark · Jan 31, 2007

Welllll, It seems like I'm the last person on CB to do this mod.
It's on my daily driver. If I like it, I'll do it to my trail rig.
I used a stock angled bracket that a friend powdercoated for me. A hydroboost unit off an excursion (Napa p/n: 52-7357), my stock master cylinder (front disks, rear drums), and Russell fittings and hoses with the following p/n's which differ slightly than other write-ups.
1: 11/16-18 to 6AN Summit p/n: AER FBM 2965 (for stock power steering box high pressure inlet)
1: 5/8-18 to 6AN Summit p/n: RUS-640380 (for Saginaw pump high pressure outlet)
1: 6AN to 16mm-1.5 Summit p/n: AER-FBM2608 (for Hboost high pressure outlet)
1: 6AN to 18mm-1.5 Summit p/n: AER-FBM 2608 (for Hboost high pressure inlet)
4: 6AN to 6AN 90 degree hose fittings Summit p/n: Rus-620421 (or you could use 6AN to 6AN 45 degree RUS-620411)
6' Russel Power flex hose Summit p/n: RUS-632610

I cut off the H-boost push rod and welded a threaded spacer on it and cut off a matching bolt so I could screw a yoke end that I got at the hardware store (thread is 3/8 - 24). It was a little long so I cut the spacer down, I also cut the spacer to facilitate a good weld.

Mark · Jan 31, 2007

What I wasn't sure of was the master cylinder pushrod.
I just removed the stock pushrod, made sure it fit into the Hydroboost well, and shortened it 2 7/8" to match the exit length of the push rod from the stock vacuum booster. I rounded the cut end on a bench grinder.

Mark · Jan 31, 2007

And here it is mounted.
It sure is easy to apply the brakes.
Not that it was hard with the vacuum booster.

Broncos n' VWs · Jan 31, 2007

Good job! Your's sure looks pretty.

Desert Thrasher · Feb 1, 2007

I use the same Hydrobooster. Instead of using the square tubing for a spacer I machined a piece of aluminum about 1 1/2" thick, but it made my mastercylinder sit close to the inside fender and the hood didnt close. How close is your mastercylinder to your fender?
Im making a new mount plate that will lower the Hboost unit and I milled down the mastercylinder so everything should clear now.

thesnake · Feb 1, 2007

Actually Mark, I think I'll be the last. I haven't even got the body on the frame yet and I've had hydroboost sitting around longer than I've had the frame lol....

You've done an excellent job!!!

J.D.

jaroh · Feb 1, 2007

Your not the last. I am happy to have the ch**y disk conversion. It is alot better than the one brake that I had when I bought my $500 bucket of problems. One upgrade at a time I guess. Good luck.

Duane

Tito · Feb 1, 2007

I've still got mine sitting in a box in the garage. Good job on the install and thanks for the good pics and info. I need a garage camera so I can take pics in the middle of my projects, I never think about it till I'm done.

A&Mbronco · Feb 1, 2007

Looks good, I thought the superduty units were supposed to bolt up to the eb master cylinder w/o any mods though; assuming that the excursion one is the same as a superduty.

Mark · Feb 2, 2007

Thanks guys!

A&Mbronco said:
Looks good, I thought the superduty units were supposed to bolt up to the eb master cylinder w/o any mods though; assuming that the excursion one is the same as a superduty.

Yeah, it bolts right up to the master - no modifying. My hboost did not come with a master cylinder pushrod, so I had to use the stock master cylinder push rod from my vacuum boost unit.

Desert Thrasher said:
I use the same Hydrobooster. Instead of using the square tubing for a spacer I machined a piece of aluminum about 1 1/2" thick, but it made my mastercylinder sit close to the inside fender and the hood didnt close. How close is your mastercylinder to your fender?
Im making a new mount plate that will lower the Hboost unit and I milled down the mastercylinder so everything should clear now.

That square tubing I used is 1". I pretty much centered the H-boost to the bracket opening that it bolts to. You can see the top tube is down about 1/2" from the top of the bracket and the bottom tube is almost flush with the bottom of the bracket.
There is about 3 1/2" to 4" clearance from the end of the master cylinder to the fender. I can take a picture if you like.

trailpsycho · Feb 2, 2007

I have a superduty unit that looks identical...I was debating about using its MC, although the Thunderbird (4 Wh Disc) MC has been recommended. I really appreciate all the detail in your write up, Mark. I was contemplating removing the mounting plate from the HB and replacing it with a 1/8" plate drilled to match the stock eb angled bracket. Did you redrill the angled bracket or the HB mounting bracket? It looked like the HB bracket from one of the pics. I wasnt sure how to address some of the push-rod length issues and such, so this is a great help. Thanks a ton.

I am still at least 1.5 months or morer away from this. I did get the call this morning; my tub, and the rest of the body is done at the media blasters!! Now its off to paint.

John

Desert Thrasher · Feb 2, 2007

Mark Troy said:
That square tubing I used is 1". I pretty much centered the H-boost to the bracket opening that it bolts to. You can see the top tube is down about 1/2" from the top of the bracket and the bottom tube is almost flush with the bottom of the bracket.
There is about 3 1/2" to 4" clearance from the end of the master cylinder to the fender. I can take a picture if you like.

Yea a pic would be cool, thanks.
Heres some test fit pics of my setup. I went with the 1 1/2" spacer because I didnt like the way the nose of the Hboost went in so far on the angle bracket. It didnt look like there would be enough travel for the pushrod. But now I might mill a 1/2" off my spacer since your setup seems to work fine.

Mark · Feb 8, 2007

Cory, here's those pics.
There's approx 3" clearance from the end of the MC to the side of the fender.

John,
Yes I did remove the Superduty Hboost plate to redrill the mounting holes. I left the angled bracket alone. Took some channellocks (is that one word or two?) to loosen that big nut holding the mounting plate on the hboost.
I painted it Hammerite silver after I marred the surface.
How'd the blasting and priming of your body go?

Desert Thrasher · Feb 8, 2007

Wow, thats a lot more clearance then I have. Ill have to take a pic to show you. Thanks for the pics.
I think Ill be milling about a 1/2" off my spacer now. Off comes the hydroboost again, 3rd times a charm right?

72Sport · Feb 9, 2007

Desert Thrasher said:
Wow, thats a lot more clearance then I have. Ill have to take a pic to show you. Thanks for the pics.
I think Ill be milling about a 1/2" off my spacer now. Off comes the hydroboost again, 3rd times a charm right?

Mark has a stock 76/77 bracket and yours is a late model Duff. They are not the same bracket. The just appear to be the same in the pictures.

ztoolman44 · Feb 9, 2007

72Sport said:
Mark has a stock 76/77 bracket and yours is a late model Duff. They are not the same bracket. The just appear to be the same in the pictures.

So does this mean that the stock bracket is the preferable one for this particular conversion? Does anyone make a reproduction stock bracket?

Desert Thrasher · Feb 9, 2007

I didnt know there was a difference. Is it the angle? Or?

pushrods and yet another Hydroboost (my install)

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