Brake Boot

[SCFFR]

After I finished the interior carpet, I attempted to install the FFR brake boot that came with the kit but didn't have much luck. It seems to be at least twice as big as it needs to be so the material folds over a couple of times. Also, the frame around the base broke in several spots. Thought it was some type of wire but it wouldn't have snapped so easily. My options are to replace that base frame with a piece of stronger wire (like a coat hanger) and then have the boot cut to take out the excess material and stitched back up for a better fit. Does anyone make a boot that can be used in place of the FFR one? I figure I can probably buy a new one for the cost of modifying the old one.

Thanks.

[edwardb]

Just mocked up the same part in my Mk4 a couple of weeks ago. I agree whatever material is around the edge is a little fragile. Mine broke in one place while installing. I'm going to slide a piece of wire into the sewn slot on that side, and call it good. Once in place, I don't think a problem. I would encourage you to mock it up and move the e-brake handle through the full motion required before you decide it's really twice as big as needed. Most of the material is needed to allow it to move properly without any restrictions. It really looks just fine (and normal) once installed and in place.

I put 10-32 nutserts in the aluminum trans side wall around the perimeter of the opening, and used black 10-32 machine screws and finish washers to hold the boot in place. Did the same thing on my Mk3 build. Looks nice, plus is much more serviceable than just sheet metal screws into the aluminum. This is a picture of the finished one in my Mk3. This particular Mustang e-brake handle is a little shorter than the usual one, but you get the idea. Aluminum handle and button from Mike's Replica Parts. Nice pieces.

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%203%20Roadster%20Build/Brakes/IMG_0815.jpg

[skullandbones]

Cool idea on the nutserts, edwardb! Thanks, WEK.

[SCFFR]

Thanks Edward.

Agree that whatever was used for the boot base frame was pretty weak. Since it looks like I will have to have the FFR boot reworked, will make the base smaller and install a stronger wire. Had bought the handle from Mike which made the boot a real tight fit so will make the opening a little bigger. Good idea on using the machine screws!

Ron

[Gumball]

Ron,

Not sure if you're using the Replica Parts brake lever cover, but here's what mine looks like after a little time in the lathe. I wanted to round off the sharp angle on the tip a bit, make it a little thinner, and add a ridge near the bottom - all in an effort to get a bit more period-correct look out of it.

http://i845.photobucket.com/albums/ab15/CCRsAC/img_4114.jpg

[SCFFR]

Thanks Chris..........................does look better with your modification.

Ron