E32 735i Brake booster conversion.
Wrote this up as I never found the consolidated info in one spot. I just did the e32 '35i Booster + mc swap. easy days, no welding. I did not use the bracket and mounted the booster direct to the firewall. As a side note the mc i was using, needed to join the two front brake lines via a T section.
Will launch a write up soon on my entire m52 conversion, but see below.
Need a bench grinder or the like
adjustable plumbers grips
dremel
drill
vice
a tap and dye, picked up for $25
Solution
Grind down the e32 735i brake booster shaft with a grinder wheel evenly around the entire shaft, then run a tap and dye all the way down the shaft, cut off the excess...
I was replacing a golf mk2 gti booster, which was cooked.
1. Remove rubber shroud etc from the booster.
2. Rotate the booster on a bench grinder, evenly and slowly using the grips to hold the shaft even, and stop frequently. Grind it down as close to the thread height as possible, and as far up the shaft as you can.
3.Almost close enough. I used a little oil to try as you want keep the temp low due to rubber seals etc nearby.
4. Tap and die, not sure which thread it was, most likely a common 10mm, that will come in any standard set.
After a bit of faffing around, i ended up securing the booster shaft in a pair of adjustable plumbers grips, that were then clamped in a bench vice. You need to clamp the shaft as close to the pvc as possible.
Oil regularily, work the die back and forth carefully.
sweet.
Now measure up the length of the shaft needed, obviously, don't screw this up by cutting too much. I mounted it in the firewall to check (twice).
Remember to leave the die on when cutting.
In my case I had to move my booster away from the m50 airbox. I did this by slotting two securing holes towards the wheel arch with a drill and dremel. To maximise the space while I was at it, I also took to the main shaft hole as well with a grinder wheel in the firewall. Ghetto, but it ended up coming up ok, after taking my time, cleaning it up and priming it. I also created a 3mm plate to sit on the engine side of the firewall just to sure it up. Not sure how much space LHD cars have to play with.
I mounted the booster directly to the firewall, allowing use of the reservoir.
Wrote this up as I never found the consolidated info in one spot. I just did the e32 '35i Booster + mc swap. easy days, no welding. I did not use the bracket and mounted the booster direct to the firewall. As a side note the mc i was using, needed to join the two front brake lines via a T section.
Will launch a write up soon on my entire m52 conversion, but see below.
Need a bench grinder or the like
adjustable plumbers grips
dremel
drill
vice
a tap and dye, picked up for $25
Solution
Grind down the e32 735i brake booster shaft with a grinder wheel evenly around the entire shaft, then run a tap and dye all the way down the shaft, cut off the excess...
I was replacing a golf mk2 gti booster, which was cooked.
1. Remove rubber shroud etc from the booster.
2. Rotate the booster on a bench grinder, evenly and slowly using the grips to hold the shaft even, and stop frequently. Grind it down as close to the thread height as possible, and as far up the shaft as you can.
3.Almost close enough. I used a little oil to try as you want keep the temp low due to rubber seals etc nearby.
4. Tap and die, not sure which thread it was, most likely a common 10mm, that will come in any standard set.
After a bit of faffing around, i ended up securing the booster shaft in a pair of adjustable plumbers grips, that were then clamped in a bench vice. You need to clamp the shaft as close to the pvc as possible.
Oil regularily, work the die back and forth carefully.
sweet.
Now measure up the length of the shaft needed, obviously, don't screw this up by cutting too much. I mounted it in the firewall to check (twice).
Remember to leave the die on when cutting.
In my case I had to move my booster away from the m50 airbox. I did this by slotting two securing holes towards the wheel arch with a drill and dremel. To maximise the space while I was at it, I also took to the main shaft hole as well with a grinder wheel in the firewall. Ghetto, but it ended up coming up ok, after taking my time, cleaning it up and priming it. I also created a 3mm plate to sit on the engine side of the firewall just to sure it up. Not sure how much space LHD cars have to play with.
I mounted the booster directly to the firewall, allowing use of the reservoir.
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