|
|||||
| http:/www.4x4wire.com/toyota/projects/roktoy8/ | Short Cuts | ||||
|
|
|
||||
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........
| Related Links |
| Please support 4x4Wire by visiting our featured sponsors | ||||||
|
||||||
|
| 4X4Wire Portal | About 4x4Wire | Search 4x4Wire | TrailTalk Forums | Advertiser's Guide | |
