Anyone ever made a power brake booster bracket out of aluminum? - The 1947 - Present Chevrolet & GMC Truck Message Board Network

SnS C10 · 01-24-2016, 10:17 PM

Going to attempt this tomorrow at work. I am a machinist so i figured what the heck might as well try it. If it doesn't workout, for sure I'm buying one from captainfab. His makes more sense anyway, dollar and speed wise, but I like to make design and machine things. I'll let you know how it turns out

cv65 · 01-24-2016, 10:33 PM

seen this on ebay http://www.ebay.com/itm/1960-1966-Ch...EKbSkvoE0B8xrQ

SnS C10 · 01-25-2016, 02:23 AM

Yea that's not going to work. Mine will be a solid chunk of 6061-t6 and be machined into a very nice piece. I'll post pictures when complete

Juice63 · 01-25-2016, 11:35 PM

Quote:

Originally Posted by cv65

seen this on ebay http://www.ebay.com/itm/1960-1966-Ch...EKbSkvoE0B8xrQ

I purchased this item. Great quality and got it fast and at a good price. When it is on I will post pix.

SnS C10 · 01-26-2016, 01:41 AM

Couple pictures. Mine piece will be a fully enclosed unit. Won't be able to see any hardware. It will look like a solid aluminum block and that's its. Almost done with it, just need to make a few adjustments.

SnS C10 · 01-26-2016, 05:45 PM

I ended up modifying the bracket quite a bit more. I'm happy with the end result and it should look good on the truck. Here are a few pictures

**slepysal** · 01-26-2016, 11:15 PM

very nice !!

siggyfreud · 01-28-2016, 08:04 PM

As someone who is just getting into machining and routing that piece looks like it was a bit complicated. Maybe not from a design perspective, but looks like you may have had to flip it a few times to mill all the sides, unless you have a $$$ machine that will turn it all for you.

SnS C10 · 01-28-2016, 08:14 PM

SiggyFreud your correct. Mill both ends for parallelism. Do all the detail work like counterbores and bolt hole locations. Mill the profile. Turn part on end at 45 degree angle, 4 times for clearance for the bracket to booster bolts. If I had an indexer, much faster. I could machine this parts in about 25 minutes if I refined the process a bit

siggyfreud · 01-28-2016, 08:23 PM

Yeah sounds like a pain. I'm still learning/refining my process to do 2-sided cutting since I don't have a good edge finder. Right now I'm zero'ing my work at dead center, and just using measurements to find that center. Then I cut/drill through into some spoil material at two locations to set an index and use a bit or dowel as my location tool. Very much a pain in the butt.

I definitely had some crazy idea that this would all be much easier to jump into than it is haha.

SnS C10 · 01-29-2016, 02:13 AM

No problem captainfab. And just as I stated, one of the machines is down.

01-24-2016, 10:17 PM	#1
SnS C10 Registered User Join Date: Jul 2004 Location: Lomita, Ca Posts: 1,225	Anyone ever made a power brake booster bracket out of aluminum? Going to attempt this tomorrow at work. I am a machinist so i figured what the heck might as well try it. If it doesn't workout, for sure I'm buying one from captainfab. His makes more sense anyway, dollar and speed wise, but I like to make design and machine things. I'll let you know how it turns out

01-24-2016, 10:33 PM	#2
cv65 Registered User Join Date: Jan 2015 Location: usa Posts: 335	Re: Anyone ever made a power brake booster bracket out of aluminum? seen this on ebay http://www.ebay.com/itm/1960-1966-Ch...EKbSkvoE0B8xrQ

01-25-2016, 02:23 AM	#3
SnS C10 Registered User Join Date: Jul 2004 Location: Lomita, Ca Posts: 1,225	Re: Anyone ever made a power brake booster bracket out of aluminum? Yea that's not going to work. Mine will be a solid chunk of 6061-t6 and be machined into a very nice piece. I'll post pictures when complete

01-26-2016, 01:41 AM	#5
SnS C10 Registered User Join Date: Jul 2004 Location: Lomita, Ca Posts: 1,225	Re: Anyone ever made a power brake booster bracket out of aluminum? Couple pictures. Mine piece will be a fully enclosed unit. Won't be able to see any hardware. It will look like a solid aluminum block and that's its. Almost done with it, just need to make a few adjustments. Attached Images

01-26-2016, 05:45 PM	#6
SnS C10 Registered User Join Date: Jul 2004 Location: Lomita, Ca Posts: 1,225	Re: Anyone ever made a power brake booster bracket out of aluminum? I ended up modifying the bracket quite a bit more. I'm happy with the end result and it should look good on the truck. Here are a few pictures Attached Images

01-26-2016, 11:15 PM	#7
slepysal Registered User Join Date: Oct 2006 Location: San Jose NOR*CAL Posts: 3,080	Re: Anyone ever made a power brake booster bracket out of aluminum? very nice !! __________________ 1960 Apache long bed fleet L6 250 Clifford intake 2 bbl carb. Langdon cast headers with dual exhaust and bellflower tips. T-5 5 speed, power steering and power disc brakes. "Over, Around or through it... "

01-28-2016, 08:04 PM	#8
siggyfreud Registered User Join Date: Jun 2012 Location: Portland Posts: 1,330	Re: Anyone ever made a power brake booster bracket out of aluminum? As someone who is just getting into machining and routing that piece looks like it was a bit complicated. Maybe not from a design perspective, but looks like you may have had to flip it a few times to mill all the sides, unless you have a $$$ machine that will turn it all for you. __________________ Current Build - Project "Ghost of Poseidon" 72 C10 Pro-touring build Previous Build - 66 GMC Pro-touring build. Sold.

01-28-2016, 08:14 PM	#9
SnS C10 Registered User Join Date: Jul 2004 Location: Lomita, Ca Posts: 1,225	Re: Anyone ever made a power brake booster bracket out of aluminum? SiggyFreud your correct. Mill both ends for parallelism. Do all the detail work like counterbores and bolt hole locations. Mill the profile. Turn part on end at 45 degree angle, 4 times for clearance for the bracket to booster bolts. If I had an indexer, much faster. I could machine this parts in about 25 minutes if I refined the process a bit

01-28-2016, 08:23 PM	#10
siggyfreud Registered User Join Date: Jun 2012 Location: Portland Posts: 1,330	Re: Anyone ever made a power brake booster bracket out of aluminum? Yeah sounds like a pain. I'm still learning/refining my process to do 2-sided cutting since I don't have a good edge finder. Right now I'm zero'ing my work at dead center, and just using measurements to find that center. Then I cut/drill through into some spoil material at two locations to set an index and use a bit or dowel as my location tool. Very much a pain in the butt. I definitely had some crazy idea that this would all be much easier to jump into than it is haha. __________________ Current Build - Project "Ghost of Poseidon" 72 C10 Pro-touring build Previous Build - 66 GMC Pro-touring build. Sold.

01-29-2016, 02:13 AM	#11
SnS C10 Registered User Join Date: Jul 2004 Location: Lomita, Ca Posts: 1,225	Re: Anyone ever made a power brake booster bracket out of aluminum? No problem captainfab. And just as I stated, one of the machines is down.



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