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  #71  
Old 09-09-2012, 10:35 AM
keith keith is offline
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That looks fantastic. The table saw trick is a new one on me.
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  #72  
Old 09-09-2012, 10:47 AM
NYsquarebird58 NYsquarebird58 is offline
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Quote:
Originally Posted by byersmtrco View Post
Ah !!! Memories !!!
Of one of the biggest cans worms I've
ever opened !!! But . . . at least she stops
good.

Glad yer ok.
Your project looks good. You'll be happy end result.
Hope you kept some strong pain killers for the migraine
or two you're sure to get.
Wanna triple your fun? Add sway bars at the same time.
Ha! Wish I had those painkillers yesterday. I was getting a migraine trying to figure out where I could source some 2"x2" square tubing on a Saturday.

It finally came to me when I was sitting on the steps looking out at the driveway. I looked at the back of my Suburban, saw the hitch and the light bulb went off! It tell ya', it was a eureka moment!
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  #73  
Old 09-09-2012, 10:59 AM
NYsquarebird58 NYsquarebird58 is offline
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Quote:
Originally Posted by keith View Post
That looks fantastic. The table saw trick is a new one on me.
Thanks Keith! I've never really fabbed anything out of metal before, but I've built all kinds of things out of wood over the years. I guess using the table saw for repeated precise cuts just seemed logical to me.

This whole thing was a big learning curve for me. I know it probably sounds silly, but the most challenging part for me was drilling the holes. I just couldn't get that 3/8" drill bit to drill all the way through that 1/4" steel. I burned up a few bits on the first hole alone.

I thought I was doing it correctly. I started with small bits and worked my way up, but by the time I got to 5/16", I was having a hard time cutting through.

I called Dave up and he was able to diagnosed my problem. It turns out I was drilling too fast. I slowed that drilled down, applied more pressure and boy that made a world of difference.
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  #74  
Old 09-09-2012, 11:03 AM
NYsquarebird58 NYsquarebird58 is offline
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Quote:
Originally Posted by DKheld View Post
Genius - shear genius.

Yep - the disc brake conversion is 1 can of worms.

Adding factory air to a non-A/C car is a whole case....

Man - you're going to be back on the road before you know it.

Eric
Thanks Eric! I'm hoping to be able to cruise this old bird before winter comes.
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  #75  
Old 09-09-2012, 11:08 AM
NYsquarebird58 NYsquarebird58 is offline
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Quote:
Originally Posted by gaffney1951 View Post
kinda fun making your own parts. I never throw away steel, you will always find somewhere to use it. Mike
Very true. With what I learned yesterday, I'm sure I'll be taking on more metal working projects in the future.

Now I've just gotta' get my hands on a welder...
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  #76  
Old 09-09-2012, 01:00 PM
NYsquarebird58 NYsquarebird58 is offline
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Here are the brackets curing in the sun.

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  #77  
Old 09-09-2012, 03:59 PM
NYsquarebird58 NYsquarebird58 is offline
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Went ahead and painted the hockey stick. Someday that engine compartment will get painted, but at least for now everything brake related will be nice and clean. I even got a new set of stainless steel clevis pins. I'll be sure to lube all the joints before I put everything back together.
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  #78  
Old 09-10-2012, 10:08 AM
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DKheld DKheld is offline
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Extending the booster out between the booster and the bracket rather than between the booster and the firewall seems to be a bonus. No need to worry with also extending the pedal bracket to match. That all stays stock and your pedal height is not changed. (one less thing to worry with) and it's a real pain to get that pedal bolt in and out unless you just like standing on your head.

Both the factory kit and the bracket I made needed to extend the stock pedal bracket (extended out and up on the factory kit).

Factory kit


My stuff


(Both designed to go between the booster bracket and firewall)

Eric

Last edited by DKheld : 09-10-2012 at 10:20 AM.
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  #79  
Old 09-10-2012, 09:29 PM
lawyercalif lawyercalif is offline
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I do not understand why you would need to cut and weld the Jeep bracket. Mine works fine as is in mockup.
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  #80  
Old 09-10-2012, 09:40 PM
NYsquarebird58 NYsquarebird58 is offline
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Quote:
Originally Posted by lawyercalif View Post
I do not understand why you would need to cut and weld the Jeep bracket. Mine works fine as is in mockup.
Last week I mocked everything up using the jeep bracket. I felt that it pushed the whole setup out too far. The master cylinder was very close to the wheel well and the threaded rod coming out of the booster was to short to reach the brake pedal linkage. it could have definitely worked if I used a rod extension but it just seemed to hang out there too far for my liking.
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