Converting manual brakes to power

[jay2002]

Hey Guys,

I'm rebuilding a 72 bronco that originally had a 6 cylinder with manual brakes and manual steering. i opted for a vacuum booster instead of hydra-boost and i'm now having clearance issues with the master cylinder hitting the hood. Has anyone else ever had this issue?

Thanks, Jay

 

[Jfryjfry]

Do you have the angled bracket that redirects the master and booster?

 

[79INA69]

I had this problem too. I have a fiberglass hood from who knows where that must be an early production. It was hitting on mine where a wood rail reinforcement that runs front to back on the hood was. I paid $50 for my hood and it wasn't painted so I just notched the area on the hood. I noticed the newer hoods don't seem to have wood any longer. Some master cylinders sit higher than others too

 

[DirtDonk]

Which mount did you go with Jay? And which master?
There have been many over the years that have had one clearance issue or another. Whether it was hitting the wheel well, or the hood, it does seem to crop up now and then.

My recollection is that most of them were cured with a simple addition of a spacer under (in the case of hitting the hood) the top bolts of the angle bracket. Whether a plate of your own making, or the more common washer(s) it usually does not take much.

Got pics of yours? How's the clearance everywhere else?

Good luck.

Paul

 

[SteveL]

Like paul said many just use washers behind the top of the bracket. I think this happens with the newer brackets meant for the smaller booster mc combo. The original stock and early Duffy brackets aimed down a touch and you had to cut or dent the inner fender for clearance. 76-77 Broncos with stock power brakes came with a modified inner fender to compensate. Common boosters for the later bracket are from a mustang2 or the newer gm style

 

[jay2002]

i do have the angle bracket set up. not sure how to add pics to this thread, otherwise i would.

 

[Broncobowsher]

There are two different versions of the power brake booster bracket. The factory bracket sets the master cylinder and booster a little lower. The inner fender is different to clear the master. If you put a factory power brake on an early body you have to modify the inner fender for clearance.

The other version is the aftermarket. To keep from having to modify the inner fender the booster and master sit a little higher. If I remember right it takes a smaller diameter (and often a dual diaphragm) since it sits higher.

 

[jay2002]

If there are two, will the aftermarket booster work with the factory bracket? I'm not too keen on the "washer" fix. Thanks for the help here.

 

[jay2002]

Just following up on this, Is there a specific bracket that i can get for this? I've got at least 3.5" between the bottom of the master and the inner fender. I see the link to insert image, but when i click on it, it prompts me at input the URL of the photo. Will that add the photo to the post?

thanks, Jay

 

[DirtDonk]

First, which bracket and master did you buy?

For pics, you can only upload directly to the discussion from your device as a contributor for 12 bucks a year. Otherwise it's asking for a link because the other method is to us an online image hosting site and then post the link here. It will show the picture instead of just the link.
In the meantime you can upload images to your "garage" and "gallery" functions in your User CP above. Best is to become a contributor of course, but that justification might depend on how much you think you'll get out of it. You've been here a long time already, so should be able to tell if it's worth it to you at this time or not.
But it's definitely easier to upload images directly to the discussion.

Paul

 

[jay2002]

i've attached pics. Thanks,

 

[DirtDonk]

Yep, lots of room down below!
I assume there's no available space in the holes to move it down, and I get that the washer thing isn't your cup of tea. But I'd seriously consider testing the waters with washers, to see how much you need, then simply buy/make spacers for the top bolts.

Me personally, rather than spacers over the individual bolts, I like the idea of a plate to encompass just the top two bolts, maybe 3/8" thick or so. Not as good as a machined tapered plate for all four perhaps, but still looks better than washers.

Not sure what else to do, other than lowering the attaching points. Maybe a little at the firewall, a little at the booster-to-bracket interface.

Curious what others say.
And thanks for becoming a contributor! Works pretty slick to be able to post right up and keeps the site strong with contributions.

Paul

 

[jay2002]

I'll try some of the options tomorrow. If washers work, I'll come up with a plate. Being able to post the pics is more than worth the price. Thanks, jay

 

[Skinnyr1]

Can you cut the bracket only above the rubber boot in picture two, bend down the bracket slightly, and then reweld? From the pics, it appears that the angle would be ok and all you would need is to add in a small amount to get it to angle down.