How to shorten 320i brake booster rod?

[dtmauto]

I'm trying to install the 320i booster in my s50 swap project. Seems to me, the rod needs to be shortened almost 3" to be the same length as the original. It looks like it will be difficult to re-thread after shortening the rod because before cutting threads, it must be turned down to a smaller diameter as the original end. Is it possible to remove the rod from the booster? If I could chuck it up in a lathe it would easy. Thanks-

[325Projectz]

I cut mine right where the threads end, then cut down the shaft down to proper length (3-4 inches) minus the thread length section and then welded the 2 piece together. You don't have much room to weld. All so I didn't have to rethread, much easier that way if you ask me.

Make sense?

[Addissimo]

I took the rod out and put it on the lathe then threaded it. Very clean.

-Addis

[325Projectz]

Addis, how did you get the rod out? I thought about doing it that way but didn't want to screw up the booster. Post some pics up of your car!

[Addissimo]

Keep in mind this was a year ago... but if i remember correctly, I took the protection boot off, and the master cylinder, and it seems like there was some bolts that kept the whole push-rod assembly in the booster. I was working 3 jobs and rebuilding my car at that point- so I dont remember much unfortunately. Ask joshh if hes willing to take his apart to tell you, hes now the owner of my old booster as I'm running the ix booster :) haha... that'll fly.

As for posting pics of my car-
Here is one ;)

Its really not that bad- My engine is in again... I'm still fitting sds and the process is a bit slow with the weather/my ambition. Tomorrow The wiring harness will be done, as with the vacuum system hopefully. I have no interior in my car right now- that'll go in thrusday along with my vibration dampener (with trigger magnets) and hopefully it'll be running by the end of the weekend. I've still got to get some spark plug wires made. I'll get some pics of the random things i've done up here after while.

[325Projectz]

I hope you don't leave that stuff out overnight! Take pics of your new harness and all that other stuff, too.

[dtmauto]

Yeah, I've tried to remove the rod and gave up thinking it wasn't possible w/o separating the booster. I'll take another look. Maybe I'll just find a good local welder.

[Brew]

Took my buddy with a die cutter and a welder about 10 minutes. He just cut the rod off of the stock booster and welded it to the cut-off 320i booster rod. Works great, no problems whatsoever.

[Addissimo]

Yeah, I've tried to remove the rod and gave up thinking it wasn't possible w/o separating the booster. I'll take another look. Maybe I'll just find a good local welder.

Thats probably your best solution. I really wish i remembered how I did it, but like I said- 3 jobs... fucks with your head.

I need to start taking pictures of this shit- i just hate getting my camera dirty.