Alfa Pages

Eddie W · Posted: Sat Jan 03, 2004 11:43 pm Post subject: Brake Booster Brace

Something I've made and fitted to two of our cars is an adjustable brace that pushes on the end of the master cylinder and transfers some of the load to the engine firewall. I fitted the first one to my car and tried it with the result that I felt there was a detectable improvement. However, bearing in mind that subjective impressions are difficult to quantify I took it off again to see if I noticed its loss, which I did. Having decided that if you can discern a definite difference it was worthwhile I then duplicated it for daughters car. Now prior to this exercise her brakes had the edge on mine with new rotors and pads, but after fitting the brace mine were more positive in pedal feel so that there was more finesse and accuracy. But with a brace fitted to hers they are again the better brakes.
The unit is very simple to make and fit so some of you may be interested. I hope to put up a pic later but here is a rough description. In the end of the master cylinder is a small depression from the original machining . The brace consists of a piece of threaded bolt about 20mm long which threads into a tube nut which is ground to an angle on the rear face to match the angle between the firewall and the master cylinder and is welded to a small mounting plate. The threaded rod is ground to an acute point to engage in the afor mentioned dimple in the end of the master cylinder and has a small flat filed on each side of the point to make it adjustable by spanner. It is then locked up with a very thin locknut. The brace is positioned and the firewall and plate drilled to take 6mm bolts. Simple to make and fit,easy to remove and I feel quite worthwhile.
Regards Eddie
_________________
A LITTLE FURTHER A LITTLE FASTER

gritsop · Posted: Sun Jan 04, 2004 12:10 am Post subject:

Hi,

Something more or less the same has got Scott Sander in his website for better braking effect.
He also has some pictures and a patern for making one.
Does yours look like Scott's?
It hears like a good idea wich I also plan to implement (as long as it stops raining) Rolling Eyes

Regards,
_________________
Thanassis Gritsopoulos
1991 Alfa 33 1.4 IE
2001 Alfa 147 1.6 Distinctive

http://www.alfa-restoration.co.uk
Parts Shop: www.alfa-restoration.co.uk/shop

Eddie W · Posted: Mon Jan 05, 2004 9:56 am Post subject:

Hi Gritsop
I think the one on Scott's websight is a folded bracket whereas this is a threaded bolt pushing on the master cylinder, but I guess the end result is much the same. I found this unit very easy to make and fit but I have welding gear so I guess I'm biased. I must say the more I drive either car the more I'm impressed at the difference. Still waiting for the IT dept.(ie daughter)to take a pic and post it for me
Regards Eddie

_________________
A LITTLE FURTHER A LITTLE FASTER

johnboy · Posted: Mon Jan 05, 2004 11:11 am Post subject:

Hi eddie

im interested in seeind this thing as i have a weilder, sounds good

all the best john
_________________
WODA WE NEED? MORE POWER!!

Alfa gt jtdm blackline
1990 S2 16v veloce sleeping!
2002 ts gtv the wifes now
1997 seadoo gsx 800
1999 freestyle superjet

Eddie W · Posted: Thu Jan 08, 2004 10:48 am Post subject:

HI Johnboy and all.
Daughter has finally loaded pics as requested and put them on my post above. I'll be interested in any comments.
Regards Eddie
_________________
A LITTLE FURTHER A LITTLE FASTER

johnboy · Posted: Thu Jan 08, 2004 1:09 pm Post subject:

I'll be interested in any comments.

Hi eddie

Nice work chap

all you need to do is spray it white and it'll look like part of the car. Laughing

l like the way you've made it adjustable. i will be making one when i have sorted out other bits on my car,but that's ever ending in alfa world Wink

all the best
john
_________________
WODA WE NEED? MORE POWER!!

Alfa gt jtdm blackline
1990 S2 16v veloce sleeping!
2002 ts gtv the wifes now
1997 seadoo gsx 800
1999 freestyle superjet

P4 Paul · Posted: Thu Jan 08, 2004 10:49 pm Post subject: brake brace

you should start knocking them out to people who haven't got a welder or the knack to make them,i'd be very interested in one,as my brakes are pants!!!! Embarassed

johnboy · Posted: Thu Jan 08, 2004 11:59 pm Post subject: Re: brake brace

Rob · Guest

I take it it's just me that's a little concerned about the fact that you're effectively attempting to shove a nail through the master cylinder casting everytime you brake (hard) then?! Couldn't you put another nut on the thread (or use a bolt) so at least the force is being spread across the whole end of the cylinder? Please? Having said that, my mate found that a block of hardwood gently hammered into place with a 2lb lump had much the same effect... Didn't look quite as trick as your bit though!

johnboy · Posted: Fri Jan 09, 2004 7:38 pm Post subject: Re: Brake bracket

Eddie W · Posted: Fri Jan 09, 2004 10:59 pm Post subject:

Hi all
Rob, interesting point, although I'm fairly confident that the master cylinder end is robust enough as what you are doing is transfering the load that is currently lost in flexion of the footwell into hydraulic load to the brakes and the internal hydraulic pressure should act to support the cylinder end. However it could be refined in a number of ways:
Asecond locknut as suggested but this would have to be silver soldered to the bolt as it would replace the function of the flats for adjusting.It would leave a small point to locate in the dimple and take most of the load over the area of the nut face, thus supporting the cylinder end.
Using an allen keyed grub screw for the bolt. The tip could then be ground to have a small locating point and a flat face to provide more area. The mounting plate and the firewall would need to be drilled to allow an allen key to be inserted from the rear to adjust.
JOHNBOY, Go for it., if you want to make them. I donate the idea to all Alfisti
Regards Eddie
_________________
A LITTLE FURTHER A LITTLE FASTER

Scott Sander · Posted: Sat Jan 10, 2004 8:24 pm Post subject:

kewl so i can post these pics as an alternative on my web site Shocked

_________________
Scott Sander
'91 Alfa 33 Boxer 16V Monza - Awesome
http://www.sanderfamily.com

Eddie W · Posted: Wed Jan 14, 2004 12:19 am Post subject:

Hi Scott
As far as I'm concerned go for it. I tried dismantling my spare m/cyl to measure the end thickness but it is proving recalcitrant, however I'm fairly confident of the safety as the bolt doesn't have a sharp point, just a steep taper and the load should be on the taper itself. By the way the bolt dia is 12mm.
Regards Eddie
_________________
A LITTLE FURTHER A LITTLE FASTER

johnboy · Posted: Thu Mar 04, 2004 3:03 pm Post subject:

Hi Chap's

I have at last made some brake servo brace's. Laughing

using scotts idear, Wink

as i have use of a Laser at work.i got one of my
work mates to make up a program for the brace.then plyed the Laser operator with tea all night.he cut ten out,so i will have 9 for sale.what i was going to do was sell them in a kit.the brace bolts two washers and two nuts.plus i was going to spray them black,all you will need to do is drill the two holes in the engine bay and fit it.i'm willing to ship world wide at cost.if they sell then i'll get more made.i will be fitting im on saturday.i will try and upload a photo when i if it.
i was thinking of £10 as ive got to give the operator some money and i dont work for nothing,how does that sound?
let me know

all the best john
_________________
WODA WE NEED? MORE POWER!!

Alfa gt jtdm blackline
1990 S2 16v veloce sleeping!
2002 ts gtv the wifes now
1997 seadoo gsx 800
1999 freestyle superjet

P4 Paul · Posted: Thu Mar 04, 2004 4:14 pm Post subject:

PUT ME DOWN FOR ONE Smile

johnboy · Posted: Thu Mar 04, 2004 4:33 pm Post subject: