Helitool Underfloor boosted master cylinder


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Posted by Keith in Washington on Monday, December 01, 2003 at 0:35AM :

In Reply to: Joe I just sent you some pictures posted by Keith in Washington on Sunday, November 30, 2003 at 8:37PM :

I have been working on my ff PW a lot lately. Last spring on my way to the Hollister meet I stopped at Helitool and ordered a dual master cylinder kit that mounts under the floor.

The installation went fairly well but I did encounter a few minor problems as you do with each installation. When the box arrived from Ray I was really impressed with his quality of work. I took a little time gathering up some parts. While I was in the process I decided to rebush both the brake and clutch peddles and I also rebushed the clutch bearing throw out rod and since I was at it I replaced the clutch disk and did some tranny work. Ray requires that you remove the front left running board support for installation. Knowing this and that the wood blocks in my truck were rotted I made new ones out of plastic. I removed both running boards and found the supports to be rusted. I ordered new ones. Boy this was getting costly even before I got started on the brakes. One lesson learned. When you remove the running boards, the supports can do a nasty number to your side. Do not ask how I know.

Now for the brake install, that was the easier part. The first thing I had to do was remove a very thick coat of undercoat from the frame where Ray's mount went. Not easy. I ended up using a little heat. Once off I cleaned all the grease from the leaking steering box off. I Tried to fit the mount and it would not go into the frame rail. Then I noticed the stone scar on the frame. I straightened the frame and it went in. Next I drilled the other 3 holes and it snugged up fine. I test fitted the booster and master cylinder and I ran into an interferrence problem with the PTO shift lever. The master cylinder was slightly in the way. That was a simple fix, I went to the local speed shop and picked up a 7" booster and to a brake supply house and got a different master. This set up was 3+ inches shorter and all interferrence went away.

I then painted the mount and frame and ground the brake peddle mount per the instructions. The installation of the booster and master cylinder was a piece of cake as was mounting the pull rod from the brake peddle and the bell crank to the booster. I then ran new brake lines hoses. I figured 51 years of service were enough. I also put residual pressure valves in both lines as the master cylinder is very close to the level of the brake cylinders. I then moved the stop light switch back next to the master cylinder and connected everything up. I also put in a new gas line from the booster back as it was surface rusted in one place. I had a lot of problems bleeding the brakes. Not sure why. I then connected the vacuum line up. I connected it to the crank case vent line were it enters the intake manifold. The test drive was great. A total of 5" of peddle travel with lots of room above the floor left and I know that there is still a little air in the lines. Stopping power is good but I need to adjust the brakes now.

The pictures that Joe posted show the finished product from above the floor and from underneath. The master cylinder and all the lines are clearly visable as is the push rod and return spring. I added a short extention to the stop light wires and it just plugs into both ends. The vacuum line is also visable in the picture.



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