Brake Booster disection... the truth about what's in there!!

[winstontj]

Here are the pics! This weekend we chopped up a booster - partially for my booster delete project and because four guys, a sawzall, some beer and tearing up a 2002 & TR-7 wasn't enough so we had to look elsewhere.

So contrary to popular belief the spring in the booster isn't really that hard. It's not going to kill you, hurt you and with onehand you can compress it. Heck if I could do it with my bum arm then it's really not that high of a spring rate. We cut around the diameter and then cut off the square plates where the pedal box/booster and booster/MC flanges are. Todd's gonna whip up something with his MIG and shorten the 2-piece push rod into one single shorter pushrod. When it's all done it will be ready for a direct-booster delete application.

My only concern was that the spring inside wasn't that strong. I wish it was but since it wasn't that means that I'll need to do something to adjust either the hydraulic ratio or the pedal lever ratio so that I can stop my car. Either way it's going to be a slick mod to have the MC mount directly to the pedal box. So much less space, neater, cleaner and I've got something different than the rest of YOU!!! :-)

[peteinjp]

Might be worth giving them a call and asking about pedal pressure and modulation with different pad formulas. Also I had one more thought about wiring- its a good idea to run the ignition circut on a relay that is switched by the key. That can eliminate ignition noise to some degree which is a good thing when running efi, Wideband or other electronics.

[TJW]

(nt)

[Harv]

I told you so. You may have to go with a MC with a smaller bore or get bigger piston brake calipers and at least tii rear wheel cylinders if not the 320i drum set up or disc brakes.

John

[NickVyse]

Either way it's going to be a slick mod to have the MC mount directly to the pedal box. So much less space, neater, cleaner and I've got something different than the rest of YOU!!! :-)

unless of course you've got a 1600-2 or any RHD 02!

[winstontj]

I told you so. You may have to go with a MC with a smaller bore or get bigger piston brake calipers and at least tii rear wheel cylinders if not the 320i drum set up or disc brakes.

John

Already have Volvo/Girling fronts and e21 320i 250mm rears... It's a bear with the tii MC but now that this is off I will try the stock MC again. If not I'll look into different pads and that 17mm single line unit from a euro e30 316i (without ABS). I think going from the 23mm tii to a 17mm will make enough of a difference.

E30 rear discs are in the works - will that make it any better though? I'll just have to use a bias valve to even things out. Thought it would keep things the same as the 320i 250mm rears???

Thanks for all the help.

TJW

[winstontj]

unless of course you've got a 1600-2 or any RHD 02!

Did they have remote boosters? It looks odd but they use the same 20mm bore MC as the stock 2002. I'm getting hard pressed to find a dual line MC with less than 20mm bore. Really running out of options.

[NickVyse]

unless of course you've got a 1600-2 or any RHD 02!

Did they have remote boosters? It looks odd but they use the same 20mm bore MC as the stock 2002.

remote boosters - two of them on RHD cars. Same MC's

[TMK-001]

Do you still run them Nick? What M/C have you upgraded to?

[NickVyse]

I'm using a 5 series MC, either e12 or e28, can't remember, with twin e12 servos.