18-Oct-2014
Not needed but added
Heres another view of the gusset
18-Oct-2014
Fresh out of the oven
After bead blasting the bracket I shot it with some silver vein powder then topped it off with a clear powder.
18-Oct-2014
Close up of the silver vein powder
I really like this color and the clear gives it a lot of depth.
18-Oct-2014
Hydro boost rod
The new hydro boost rod needed to be cut and threaded to accept the coupling and the old rod from the Jeep.
18-Oct-2014
Tapping the steel coupling
The hardware store near me did not carry any fine thread couplings but they did have some steel spacers. I opened up the 5/16" hole to 21/64" and tapped it with a 3/8-24 tap.
18-Oct-2014
Coupling complete
My adjustment coupling is complete, drilled out and tapped to 3/8-24 threads.
Modified hydro boost rod
My modified rod is complete. I have about 1/4" of adjustment which doesn't sound like much but that little bit actually moves the pedal a great distance.
19-Oct-2014
Hydro Boost adapter bracket installed
After the powder coating cooled the adapter was ready to be installed. Some grade 8 bolts are up to the task to secure this adapter to the firewall. The final fit was great.
Hydro Boost unit bolted up tight
I ended up knocking out the OEM studs on the mounting plate from the Astro Van. I picked up some grade 8 flange bolts to couple the Hydro Boost unit to the adapter.
19-Oct-2014
Return line fitting
Instead of using a tee in the return line from the Hydro Boost I decided to run separate return lines back to the pump. Installing this bulkhead fitting was a little tricky since I didn't remove the pump from the engine. I ended up stuffing some rags in the pump then I put grease on them to catch any shavings. I also used some magnets inside the pump as an extra precaution to catch some metal shavings.
19-Oct-2014
Wrench needed
With the bulkhead having a sealing washer and a nut on the inside and hard to reach I needed to make a wrench to reach inside the pump to hold the nut while I tightened it from the outside.