Pedal cluster n brake booster installation in a pre booster body

baruch mor · 07-03-2009, 02:37 PM

Hi
thanks to MATT from the foprum n his mechanic rick from RICK'S EUROPEAN in MIAMI that even helped me to send the gear to PATRICK MOTORSPORTS at ARIZONA i got my "new toys" : 3.2 engine with after market exhaust system n chip, g50 gear, brake booster and pedal cluster for the new hydraulic clutch, quick shifter, extra oil radiator for the front and a set of calipers .

The engine n the gear will be easy to install thanks to your former posts about 2.7 to 3.2 conversion.

Now i need instructions/pics on how to change the piece of the body i got with the booster into my old 1976 body + how to fit the pedal cluster to the old 1976 ...

Here r a few pics:

baruch mor · 07-03-2009, 02:48 PM

This is the piece i got from the 1988 car with the booster and rick told me i need to cut main n weld this one - do u guys have any pics how it should be done?

zotman72 · 03:27 PM

I wonder if you can just do the take the clutch slave cylinder pedal components and transform it to your earlier pedal cluster. Reason I ask is that I did a vaccum brake booster install on an '74 and it was one of the worst PITA jobs I ever undertaken on a 911. Fortunately in my case it was racecar so I did not have make it pretty. Your current MC will stop your car just fine.
You will need to fabricate a mount plate for your new vaccum booster & MC, I used 1/8 " aluminum plate. Cut a box hole to send the rod and mount bars up from the pedal cluster. Get some metric 4' brake lines and brake pliers and fab up the new lines up into the trunk from the old MC location. Finally you have to run a vaccum line from the engine compartment to the trunk. I used the heater lines but fishing up there was a major hassle. Good luck!

zotman72 · 07-03-2009, 03:23 PM

Here are some pictures of the plate I fabricated for mounting a vaccum booster and master cylinder into a '74 911 without swapping out the sheet metal. I used sheet metal screws to secured it. YMMV

john walker's workshop · 07-03-2009, 03:33 PM

RHD? basically you trim off any extra metal from your donor piece that you already have on the car body. if there's a different shape on the donor chunk that's not on your body already, that's what you keep. then you carefully cut out the hole for it in the body, using a couple of line-up points, like the edge of the smuggler's box and the edge of the oval hole for the plastic air valve, so it ends up in the proper place. you also need to remove the gas tank and fit in the reinforced area in front of the pedals, which bulges out somewhat behind the tank. butt weld edge to edge, grind flush and finish.

LM3929 · 03:37 PM

As JW has said and there is a couple of good threads showing you everything you need to do. Lorne M.

baruch mor · 07-03-2009, 03:48 PM

thanks JW - i figured out i need to remove the gas tank.
LM3929 could u give me a few links? i couldnt find anything

zotman - tnx for the pics but i dont want a pita job on my car ;-)

LM3929 · 07-03-2009, 08:23 PM

I havn't found them yet but I know their here, I was going to have to do the same job on my brother in laws slant nose whataby

baruch mor · 07-04-2009, 03:44 AM

thanks im still looking for the pics or links

Jim Williams · 06:46 AM

Here are some links I have saved for such a conversion:

Power brake upgrade
What do I need to upgrade to power boosted brakes?
http://home.nycap.rr.com/wmv/index.htm (Bill Verburg's website)
The Journey Begins- 911ST recreation
You'll have to look through this last one to get to the photos..

Hope this helps...

baruch mor · 07-05-2009, 12:19 AM

thanks jim
let me ask another question:
by moving to G50 with hydraulic clutch can i stay with the old brakes n pedal cluster and just replace the clutch pedal

baruch mor · 07-06-2009, 12:10 AM

Ok my body work shop got the parts and said he have a better idea : not to transplant the new piece but to make 4 studs and a hole 4 the booster - did anyone did it (better than zotman72 cause its not a track car but my weekends car) ?

john walker's workshop · 07-06-2009, 05:10 AM

around here we call that "mickey mouse". find a shop that will do it right.

baruch mor · 07-06-2009, 05:38 AM

hi jhon do u have pics on how to do it right? where to cut the sheet metal etc. ?

LM3929 · 07-06-2009, 02:12 PM

Check the piece of the old body and see that it was reinforsced

911pcars · 07-06-2009, 02:45 PM

Other than the fact you have the boosted MC assy., may I ask why?

It looks like you have 2-piston, factory calipers to install. If Carrera calipers, these are essentially the same as earlier brakes with no assist and with no traditional issues with brake pedal application effort.

I could see it with a 4-piston caliper, big brake install requiring a larger volume MC, but with stock brakes in a lighter-than-88 chassis.... this is not a small undertaking, price-wise as well as labor-wise for not much gain except less effort to press the brake pedal.

There are numerous owners with early bodies and 3.2 engines using the factory Carrera brakes w/o power assist.

Please rethink and reconsider. Keep it light(er).

Sherwood

baruch mor · 07-07-2009, 03:38 AM

hi sherwood,
im doing it because the need to put the new pedal cluster with the hydraulic clutch
please correct me if im wrong but there is no other option isnt it ?

anyway i found somebody to do it + im changing the calipers too

911pcars · 07-07-2009, 10:49 AM

Quote:

Originally Posted by baruch mor

hi sherwood,
im doing it because the need to put the new pedal cluster with the hydraulic clutch
please correct me if im wrong but there is no other option isnt it ?

anyway i found somebody to do it + im changing the calipers too

Oh, I overlooked the G50 gearbox you're trying to install. But is this gearbox really necessary? A 915 should be fine (you already have one, if in good condition). A compatible 915 flywheel and clutch assembly is all that's needed. You can sell the G50 and realize some spending money. In addition, fitting the G50 requires some costly space modifications, and it's heavier in addition to the required chassis surgery to accommodate the hydraulic clutch/boosted brake pedal assembly and associated hydraulic lines.

MHO,
Sherwood

baruch mor · 07-11-2009, 04:19 PM

911pcars allready in it - cant go backwords
anyway tnx

baruch mor · 02:42 AM

Hi again, gas tank is out of the car , what else do i need to take out of the car to cut and weld the sheetmetal of the donor car?

please need your fast answer as the car is open now...

as i c it , need to take out : pedals, left wheel and linkage (or whatever u call it) - not simple as i tot