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Old 08-18-2018, 02:58 PM   #251 (permalink)
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Well, this morning I got after the front crossmember with the plasma cutter.
Still needs lots of clean up, but the radiator will now fit. After I get the
radiator positioned I'll probably weld some angle iron across from each
frame rail and connect to the top of the bracket for the grill. That should
add enough strength back so it doesn't flex a bunch. There sure was a
lot of crud inside the crossmember.
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Old 08-18-2018, 03:14 PM   #252 (permalink)
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Nice work.

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Old 09-04-2018, 08:06 PM   #253 (permalink)
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Well, I put the tub back on temporarily so I could mock up stuff like where the brake booster goes. In order to clear the left head the booster needs to be about 12" to the left of where the brake pedal needs to go. I'm thinking of buying a second pedal assembly, mounting one to the booster and the other 12" to the right and connecting them together with a rod to transfer the motion. Anyone done anything like that ?
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Old 09-04-2018, 08:15 PM   #254 (permalink)
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Well, I put the tub back on temporarily so I could mock up stuff like where the brake booster goes. In order to clear the left head the booster needs to be about 12" to the left of where the brake pedal needs to go. I'm thinking of buying a second pedal assembly, mounting one to the booster and the other 12" to the right and connecting them together with a rod to transfer the motion. Anyone done anything like that ?
Iirc v8 early broncos w/ power brakes do some sorcery to clear the motor w/ power brakes. Invesigate.
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Old 09-05-2018, 08:31 AM   #255 (permalink)
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I used a Cherokee booster and made a custom pedal. So far it has held up well. the only problem I ran into was the pedal was hitting the floor and I was not getting full motion. I bent the bracket a little and added a gusset to it for strength.
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Old 09-05-2018, 08:52 AM   #256 (permalink)
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Iirc v8 early broncos w/ power brakes do some sorcery to clear the motor w/ power brakes. Invesigate.
Here are some pics. The uninstalled one is from Toms Broncos.
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Old 09-05-2018, 11:30 AM   #257 (permalink)
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Well, I put the tub back on temporarily so I could mock up stuff like where the brake booster goes. In order to clear the left head the booster needs to be about 12" to the left of where the brake pedal needs to go. I'm thinking of buying a second pedal assembly, mounting one to the booster and the other 12" to the right and connecting them together with a rod to transfer the motion. Anyone done anything like that ?
Sounds like a good excuse to install a Hydroboost system...

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Old 09-05-2018, 05:26 PM   #258 (permalink)
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Sounds like a good excuse to install a Hydroboost system...

Aaron Z
Nice idea, but that wouldn't solve the peddle to booster offset. I also looked at the early Bronco stuff and there's no place to mount the angled bracket they use. It would hit the motor. I knew this wouldn't be easy.
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Old 09-05-2018, 07:59 PM   #259 (permalink)
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Nice idea, but that wouldn't solve the peddle to booster offset. I also looked at the early Bronco stuff and there's no place to mount the angled bracket they use. It would hit the motor. I knew this wouldn't be easy.
Ah, I was thinking you needed to move it to fit the "can" of a vacuum booster in there.

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Old 09-06-2018, 02:30 AM   #260 (permalink)
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Thanks for showing how you went about the headlight install.
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Old 09-06-2018, 03:21 AM   #261 (permalink)
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I remember seeing some I think was Mitsubishi cars from the 80s that had the booster and MC remotely mounted with a cable from the pedal to the MC

Donít know what model but mitsu didnít sell many in the states in the 80s
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Old 09-08-2018, 03:18 PM   #262 (permalink)
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I think I may have a solution to the brake pedal offset. I have the pedal assy pictured below. I'm thinking making a new piece that fits in the center, the one with the 2 holes in it. The new piece would be bigger diameter and extend to the right with a drilled and tapped hole in the end. I'd get another of these brake pedal assy, cut off the tube on the pedal and bolt & weld it to the end. I'd mount the tube to the firewall using a hiem joint.
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Old 09-09-2018, 01:51 PM   #263 (permalink)
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Well, I got the rear corner guards roughly on and the rocker guards fitted and drilled. I also mocked up where the steering column goes and took some measurements. The brake booster needs to mount in the center of the 2 rectangular holes in the firewall, but the pedal needs to line up with the round hole in the floor just to the right of the steering column. That's an offset of appx. 12". Going to visit the local machine shop to see if they'll make the round bar I need to offset it.
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Old 09-23-2018, 01:07 PM   #264 (permalink)
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Got busy with some small stuff this weekend. Enlarged the opening for the trans/tc and the shifters. No way the stock trans cover would fit as the SM420's much larger than the T-90. The gas filler neck finally arrived so I got the holesaw out and got that positioned. Going to be slow on it for a while now as next weekend we'll be getting everything ready for our 2 week road trip to Wisconsin and back. Going to my mother's 90th birthday bash.
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Old 09-29-2018, 11:05 AM   #265 (permalink)
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Two steps forward, one step back. I got the real steering column in and there's no way I can use the headers. No realistic way to get the linkage around the header tubes, so it's back to cast exhaust manifolds.
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Old 10-28-2018, 11:31 AM   #266 (permalink)
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Got a new left side cast exhaust manifold as the old one was warped. Mocked up steering column and the brake booster/master/pedal. Also roughed in where the steering box is going to mount. The box needs to go down and forward a bit, but I have to trim up the plate it's bolted to first. Spent yesterday chasing metal for the trans cover and seat frames as the old frames are super rusty and I don't trust them to hold up.
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Old 10-30-2018, 09:14 PM   #267 (permalink)
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Whos steering column did you use?
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Old 10-31-2018, 05:37 AM   #268 (permalink)
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Whos steering column did you use?
Ididit.

https://www.ididitinc.com/

They have all different sizes and options.
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Old 11-01-2018, 07:53 AM   #269 (permalink)
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That must be a classic tilt with floor shift? How long? I ask because Im working on an early CJ too.
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Old 11-01-2018, 05:22 PM   #270 (permalink)
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That must be a classic tilt with floor shift? How long? I ask because Im working on an early CJ too.
Universal 30" Tilt Floor Shift Steering Column - Paintable Steel

https://www.ididitinc.com/i-25047845...tegory:1310134
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Old 11-04-2018, 10:41 AM   #271 (permalink)
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Well, I trimmed the plate the steering box is bolted to and moved the box a lot closer to where I want it. Trimmed up the grill to clear the box and the hydraulic lines to it. The steering shafts are looking a whole lot better.
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Old 12-26-2018, 07:36 PM   #272 (permalink)
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https://denver.craigslist.org/pts/d/...769387798.html

If I am not mistaken, here is a rear offset 44.

Might be a bit far for you though. I also noticed you upgraded the rear centered 44. Are you still dead set on the offset pair/d18 setup?
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Old 12-28-2018, 02:40 PM   #273 (permalink)
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https://denver.craigslist.org/pts/d/...769387798.html

If I am not mistaken, here is a rear offset 44.

Might be a bit far for you though. I also noticed you upgraded the rear centered 44. Are you still dead set on the offset pair/d18 setup?
I upgraded the offset D44 to one piece axles. I'm keeping the D18 t-case because I want the overdrive with the 4.88 axle gears.
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Old 12-30-2018, 12:14 PM   #274 (permalink)
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Nothing worth any pics. Bent up a brace between the bottom of the dash panel and the firewall to stiffen up the mounting where the steering column mates to the dash. Also cleaning up parts. Boring, but needed.
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Old 01-04-2019, 07:57 PM   #275 (permalink)
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I upgraded the offset D44 to one piece axles. I'm keeping the D18 t-case because I want the overdrive with the 4.88 axle gears.
Yeah I went back and looked through the thread again. It looks great! I need to get mine going...this is great motivation though.
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