Brakes and suspension



It got too dark to get decent pictures again, but I'll try to remember to get pictures tomorrow morning.



The brake line from master to "T" on the rear axle is 1/4" instead of the common 3/16" most cars or 1/2 ton trucks seem to use. I used 3/16" and don't think it will be a problem, but please tell me if there is a reason to re-plumb it.



I tried to use a junkyard 03ish Expedition with rear disk 1 1/4" master cylinder and larger booster. It was in good shape and the only one with a significantly larger master and booster that wasn't junk they had. The booster wouldn't work and couldn't be re-drilled without going past the re-enforcement plate on the inside of the firewall. The master cylinder mounted right up to the Bronco booster so I bought a new 90 F350 booster.



It might be useful to others that the stock 06 SD rear brake hose from the frame to axle fits right into the bronco with a 3/16">1/4" adapter and is probably 18" long. The lower is a "T" that is 3/16". It could likely be used on any OBS Ford.



The parking brake cables were interesting to figure out since the left cable comes out the rear. I adapted it to work with the new SD cables to the stock front cable. Only thing I had to make was cutting the adjustment rod, making a 3-4" extension out of plate attached with some old 302 rocker lock nuts, and crimping a shorter stop to match the right on the left. I used a 20 ton press and don't think it's going anywhere after testing it. I used the extra stop crimped over the plastic on the cable. There's no plastic under it now and If it slips it will only slide up to the original stop. It'll pass a state inspection and this is an auto anyways. Anybody think this is a horrible idea and have a better way?



The rear shocks are bilsteins that came with the axles, fronts are Procomps spec'd for a lifted superduty that I tried using on my 80 series Land Cruiser. I replaced them with Fox shocks due to not being stiff enough and expect to do the same. I'm trying to just get it drivable to test it out before spending money on the suspension. Most of the unknown is how the front suspension will behave and getting both ends to work well together.



I pulled the throttle pedal after mocking up alignment for the Corvette pedal. I think the original pedal pivot base will work as a base for a bracket to give the vette pedal a flat surface to bolt to.



It sits on the tires, parking brake is set and holds the truck, and brake pedal feels good considering the booster is doing nothing without an engine in it. Tomorrow I might try to connect my Mityvac and see if I can pull enough vacuum to test the brake feel.