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Old 11-03-2012, 04:53 PM   #58 (permalink)
Christ
Moderate your Moderation.
 
Join Date: Nov 2008
Location: Troy, Pa.
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Pasta - '96 Volkswagen Passat TDi
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I detailed a manual brake swap setup somewhere on here with my VW Golf as well.

I made a quick adapter plate by cutting up the old booster housing, drilling it, and bolting those sections together.

It was quick and dirty, but it worked just fine. The pedal instantly felt harder and somewhat more pressure was required to work it, but the difference was easily manageable for a "normal" person, probably even better for someone already used to manual brake systems.

To alleviate that, I planned originally on shortening the push rod (to move the brake pedal further down it's travel and get a better angle on the pedal) as well as moving the attachment point of the rod to the pedal arm up some to provide more mechanical advantage.

I daresay that with proper engineering, one could develop a leveraged manual brake system for a vehicle up to 2.5 tons capable of standing with the best assisted systems on the market for normal use.
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