2nd Generation Specific (1986-1992) 1986-1992 Discussion including performance modifications and technical support sections.

Manual Brakes conversion, clean....

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Old Dec 2, 2007 | 04:57 PM
  #1  
zbrown's Avatar
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From: scranton nd
Manual Brakes conversion, clean....

This sounds silly but I want my engine bay as clean and simple as possible. I already have a full wire tuck and the coils are inside so my next project was to get rid of the large booster portion of the master cylinder.

I removed the master cylinder + booster and then unbolted the booster from the master cylinder..... simple

next made a plate from steel to cover the existing hole..... this is not needed but it looks nice.

The booster bolts to the firewall with 4 bolts and the master cylinder has 2, It works out perfectly that the top two bolts holes for the booster are the same distance apart as the 2 bolts on the master cylinder. So this means no drilling of holes at all.

Also using these top two holes moves the fulcrum of the pedal up 3 cm.....
This which will decrease pedal effort, which is desireable since you are removing the booster

I removed the pedal to drill a new hole, and made a new adjustable rod between the pedal and cylinder, with a bolt, a file, and a drill press used as a lathe ........ looks factory

You have to trim just a very littile bit on the firewall with a die grinder for the the new rod to fit correctly.....

Put everything together and made some new brake lines..... simple simple
I spliced the new line for the rear into the existing line in the middle under the car

Everything all together maybe took 2.5 hrs...

I didnt think it would clear up as much room as it did, i love the openess of that corner now

Brake feel is very different as it is much more progressive and lockup is alot more predictable...... YES i can still lock all 4 corners without effort

Tinner gave me this idea, so thanks to him

Here is a pic of what it looks like with the booster gone... i didnt take a pic once the lines were done, but they are just as simple and look great



and here is a pic of what was removed, 5-10lbs



zac
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Old Dec 2, 2007 | 05:03 PM
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From: Lake Stevens
Wow, you can take that out? I had no clue.

So does it feel like you have the car off when you're breaking?

Definately looks very clean. Nice job.
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Old Dec 2, 2007 | 05:15 PM
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From: Pacifica
Damn, nice!
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Old Dec 2, 2007 | 05:33 PM
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From: Northern Indiana
ive been lovin your car for some time now... but this tops it! im going to do some wire tucking and and what-not, but im still going to keep my p/s and anti-lock, even though these cars look AMAZING with just the painted block and nice shiney turbo... -
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Old Dec 2, 2007 | 05:34 PM
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From: Northern Indiana
you should put a full bay pic up btw...
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Old Dec 3, 2007 | 02:28 PM
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From: Pacifica
What kind of master cyl. is the smaller one?
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Old Dec 3, 2007 | 02:29 PM
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From: Hagersville Ontario
Originally Posted by dial8
What kind of master cyl. is the smaller one?
The clutch master cylinder
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Old Dec 3, 2007 | 02:32 PM
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From: Pacifica
oh...
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