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http:/www.4x4wire.com/toyota/projects/roktoy8/	Short Cuts
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By: Jay Kopycinski - 11/2002

For brakes I used stock IFS style calipers up front and Supra disc brakes on the full floater rear. I chose to use a stock 7/8" brake master cylinder off a mid '80s Toyota 4WD truck. I did not use a brake booster to simplify the system, provide constant braking during all engine conditions, and to provide more clearance for the steering shaft.

Master cylinder mounting plate	Brake pedal mounting bracket

I fabricated a simple plate mount for the master cylinder and mounted it in my firewall area. I cannibalized a stock pedal mount assembly to get the upper mount that holds a stock brake pedal. I welded a portion of this mount to a piece of flat stock to weld to my tube chassis. To this I mounted a stock pedal that I modified to increase its length by about 50%. This will help regain some of the mechanical advantage I lost deleting the brake booster.

Complete brake pedal assembly

Since I used a piece of the factory brake pedal mount, I had retained the portion where the brake light switch attaches. This made it easy to use the stock switch and wire in functioning brake lights. A stock cylinder piston rod assembly and spring were used.

Installed master cylinder	Cab view of master cylinder	Brake pedal mount bracketry	View including brake light switch

Firewall under construction	0.090" aluminum cut for firewall

For safety reasons and convenience of mounting I chose to use a firewall constructed from 0.090" thick aluminum. I don't know how to aluminum weld so stuck with forming the interior from flat panel pieces. I welded tabs in place on the chassis tubing to provide attachment points for the firewall. I used a scrap piece of 0.060" aluminum to first mockup the firewall and decide where I need to drill all the holes for shafts, mounts, etc.

Driver side view of firewall	Pedals and steering shaft	Pedals and battery mount area	Passenger side view of firewall	ECM mount and battery + feedthru

I used a stock Toyota accelerator pedal assembly but modified the top of it to accomodate a stock Chevy throttle cable that mates to the TBI unit. The pedal assembly bolts to a tab welded to the chassis floor tubing and to a point on the firewall.

The firewall has holes to accomodate feeding the wiring harness from the engine to the ECM that is mounted on the cab side of the firewall. A Wrangler Power Products battery feedthru was used to safely route battery positive through the firewall to the starter and winch solenoids.

More to follow........