RobW
06-29-2020, 09:19 PM
So life got in the way of working on the Roadster. I unpacked everything a couple weeks back and started scratching my head. Where to start first. I had already mocked up the front suspension. This weekend, I fixed a couple things that were wrong and started torquing things down. The UCA Castle nut was sitting way past the cotter pin hole on the bolt so I backed off the bolt and used a couple 1" washers to make up the difference. The washers were a tad too wide so I clearanced them with a grinder so they slid up over the bolt. Once torqued, the castle nuts lined up perfectly with the cotter pin holes. I could not get a torque wrench on the lower castle nuts so I tightened down as much as a I could.
I then decided to work on prepping parts. I disassembled the peddle box removed from my donor (98GT), cleaned it, drilled out the spot welds and relocated the spring catch. I painted it with BBQ paint. Looks pretty good.
I then started looking at the Hydrobooster. It was pretty dirty so I spent some time at the parts washer and cleaned it up. Per the manual, I removed the snap ring and used the provided tool to remove the bolt and removed the mounting bracket. That got me wondering how it would attach. Looking ahead in the manual, I bolted the peddle box to the frame using the top two holes. I then used the provided hex bolts to secure the hydrobooster to the back side of the frame. There were a few issues. There is not enough space to use my hex wrenches in the top hole. I had to sacrifice on the grinder to get it to fit in the tight space. The provided 1" socket hex bolts are too short for the application. I used the 2" bolt on the bottom hole to temporarily mount the hydrobooster. Probably going to pick up a 1.5" at the hardware store. Anyhow, the Pushrod extended too far to catch the brake peddle. I loosened the bolt and slid the push rod end over nipple on the brake peddle and temporarily secured. I then tightened the lower brake booster bolt until tight. The push-rod is too long. It pushed the peddle up against the frame and jammed up the white plastic switch. The plunger came loose. I was able to push the peddle in but the movement was really rough. I need to look at shortening or replacing the push rod with one that fits. I will take another look this weekend. Any thoughts?
I took pictures but need to go back and reeducate myself on how to host/post. Feels like I made good progress today. It felt good to get out in the garage.
Rob
I then decided to work on prepping parts. I disassembled the peddle box removed from my donor (98GT), cleaned it, drilled out the spot welds and relocated the spring catch. I painted it with BBQ paint. Looks pretty good.
I then started looking at the Hydrobooster. It was pretty dirty so I spent some time at the parts washer and cleaned it up. Per the manual, I removed the snap ring and used the provided tool to remove the bolt and removed the mounting bracket. That got me wondering how it would attach. Looking ahead in the manual, I bolted the peddle box to the frame using the top two holes. I then used the provided hex bolts to secure the hydrobooster to the back side of the frame. There were a few issues. There is not enough space to use my hex wrenches in the top hole. I had to sacrifice on the grinder to get it to fit in the tight space. The provided 1" socket hex bolts are too short for the application. I used the 2" bolt on the bottom hole to temporarily mount the hydrobooster. Probably going to pick up a 1.5" at the hardware store. Anyhow, the Pushrod extended too far to catch the brake peddle. I loosened the bolt and slid the push rod end over nipple on the brake peddle and temporarily secured. I then tightened the lower brake booster bolt until tight. The push-rod is too long. It pushed the peddle up against the frame and jammed up the white plastic switch. The plunger came loose. I was able to push the peddle in but the movement was really rough. I need to look at shortening or replacing the push rod with one that fits. I will take another look this weekend. Any thoughts?
I took pictures but need to go back and reeducate myself on how to host/post. Feels like I made good progress today. It felt good to get out in the garage.
Rob