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For the last few years I've been designing a way to mount a vacuum boosted dual master cylinder on my 6x6 Power Wagon, while keeping the stock brake and clutch pedals. The last few months have been spent researching different parts and designing a mounting bracket for the system. This is what I've come up with so far:
This is a GM style master cylinder with 1 1/4" bore. The booster is a 7" single diaphragm unit from Tuff Stuff, and bolts directly to the master cylinder with no modifications. An 8" booster will probably fit in the same location, and a double diaphragm booster would add about 1 1/2" to the overall length. My truck doesn't have a PTO on the transmission, but from what I can tell there will be plenty of room for both the PTO and the master cylinder. This setup won't work with a rear PTO system.
The mounting bracket will look something like this:
The bracket will mount to the transfer case cross member, and should place the master cylinder under the driver's floorboard. I won't know for sure how the alignment works until the cab is mounted to the frame, sometime this year. For a long time I was trying to find a place to mount the bracket using existing bolt holes in the frame, but it never worked very well. This bracket will need 4 holes drilled in the lower flange of the cross member, which won't affect its strength.
There's still some design work to do on the bracket, but I'm 90% done (I hope). I'll post more pictures once I have the steel bracket fabricated.
This is a GM style master cylinder with 1 1/4" bore. The booster is a 7" single diaphragm unit from Tuff Stuff, and bolts directly to the master cylinder with no modifications. An 8" booster will probably fit in the same location, and a double diaphragm booster would add about 1 1/2" to the overall length. My truck doesn't have a PTO on the transmission, but from what I can tell there will be plenty of room for both the PTO and the master cylinder. This setup won't work with a rear PTO system.
The mounting bracket will look something like this:
The bracket will mount to the transfer case cross member, and should place the master cylinder under the driver's floorboard. I won't know for sure how the alignment works until the cab is mounted to the frame, sometime this year. For a long time I was trying to find a place to mount the bracket using existing bolt holes in the frame, but it never worked very well. This bracket will need 4 holes drilled in the lower flange of the cross member, which won't affect its strength.
There's still some design work to do on the bracket, but I'm 90% done (I hope). I'll post more pictures once I have the steel bracket fabricated.
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