99-04 Donor Brake Pedal Question

[Jonathan427]

Hi,

I'm using a 2000 Mustang GT pedal box for my 289, without power brakes.

The manual tells me to cut 1 1/2 inches out of the pedal, between the pivot and the bolt. If I do this, the bolt is going to be almost touching the pivot, which does not make sense. Seems to me that the stock 2000 pedal is close to the older pedal after being cut and welded.

I've marked the pedal with a 1 1/2 inch area to cut out...85468

Does anyone have any advice?

Thanks,

Jonathan

[michael everson]

I have run into this on several pedal boxes over the years. Never really figured out why Ford did some of them different. I would run it as is. Better yet, use power brakes.
Mike

[mike223]

+1, I would try it as is.


I've found at least three different OEM brake pedal ratios in SN95 pedal boxes.

Some people list a difference between 94-98 and 99-04 pedal boxes, but I don't see what it is.


Anyway, your brake pedal appears to be about 4:1 ratio, many of them are closer to 3:1.

The 1.5" cut described in the manual is designed to change a ~3:1 brake pedal to ~6:1 for manual brakes.


I am running ~4:1 with a 21mm Thunderbird MC with very good results.


The master cylinder is a 21mm bore for a 1982 Thunderbird V6.

Part number M1907 for reman ($20 + core), NM1907 for new ($32 no core) from Autozone (U.S. prices).


It's a pretty cheap and easy experiment.


I recommend thoroughly testing brakes, steering, etc during the go-kart stage to determine anything that needs to be reworked / reevaluated before the body goes on.

[Jonathan427]

Thank you both for your responses.

I've ordered both!

A 1995 Cobra SVT MC, as it has the switch for the traction control. It's a 15/16 bore, which is slightly smaller than stock.

What you guys know, and I just found out, is that a smaller bore is lower pressure than a bigger bore, so should result in a lighter pedal.

Just in case, I also ordered a Thunderbird MC as suggested. I'm in Canada, and Rock Auto does an incredible job delivering fast, easy and amazing prices. Can't recommend them enough, as my local stores are not only expensive but they never have anything I need in stock, and there's never a choice, it's cheap Chinese or nothing. At least some of the Rock stuff is US built!

Got some amazing red powder coated stock GT brakes from Rock, look really good with the FFR coilovers...

Thank you again,

Jonathan

[Norm B]

Jonathan, I have a 1996 pedal box and a shortened brake pedal available if you want it. I recently converted to power brakes so I don’t need the shortened pedal. I’ll throw in the Whitby adjustable pushrod. All yours for $100 Canadian pesos plus shipping.

Norm

[Jonathan427]

Hi, Norm, and thanks for the offer!

I'm going to stick with the setup I have, at least as far as Go Kart. After your post, I checked out the Whitby system, and I am considering that as an option. I really did not want to install the Ford Hydroboost system, as there are a lot of pipes that did not look at all pretty....

All the best,

Jonathan

[Norm B]

I followed the directions of a couple of highly respected forum members and made my own frame mod. I purchased a booster and replaced the pedal. The reservoir off the master cylinder was modified and I made a bracket to mount it beside the master cylinder. The F panel needs a hole and cover to allow the master cylinder to fit. The cover is a stainless steel pet food dish from the dollar store. I did the mod with the body on and it's not much fun. Here's a picture of the completed project.

Norm

[mike223]

I followed the directions of a couple of highly respected forum members and made my own frame mod. I purchased a booster and replaced the pedal.



What was the smallest diameter MC you tried before you went to power? - Just curious.

I autocrossed with the 21mm x 4:1 last Saturday - still very pleased.


I ran a 5/8" x 3/4" CNC 241 system for several years - I ended up dialing out all the 5/8" (rear) bias due to 5000+rpm 2nd gear let offs (+ straight on the brakes - autocross).

The ~6.5:1 pedal vs the CNC241 wasn't bad, but compared to the 21mm vs 4:1, it (6.5:1 / 241) was like stepping on a rock.


Much better "feel" with 4:1 vs 21mm.

95 Gt single piston front calipers / 89 Tbird rear calipers (old IRS).


Many, many variables (tires, spring rates, pads, expectations, etc, etc, etc).



Good luck.

Best advice - Test a lot while go-karting...