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EV Power Brakes

Another Saturday, another list.
List:

  • Vacuum Brakes:
  • Mount pump,
  • make a bracket with rubber mounts to cut down on noise.
  • Mount switch
  • wire switch and pump
  • Use feed for switch and pump from original fuse box
  • Install extra check valve
  • Make and install (mount) vacuum reservoir tank with giant clamp
  • Install muffler on pump's inlet
  • Heater, Liquid: Decide on location of under dash or right inner fender
  • Rear struts and Springs
  • Gauges
  • Repair Clutch (pedal goes to the floor)
  • Organize wiring in looms
  • Decals and emblems

    • This is an out of focused picture of the vacuum hose I used for the brake booster system. It is 3/8 inch fuel injection hose with a plastic inside liner. The heaver fuel Thinjection verses the standard fuel nose is less likely to kink, collapse or leak vacuum.This is an out of focused picture of the vacuum hose I used for the brake booster system. It is 3/8 inch fuel injection hose with a plastic inside liner. The heaver fuel Thinjection verses the standard fuel nose is less likely to kink, collapse or leak vacuum.
    Vacuum Pump MountsVacuum Pump Mounts

    When mounting the vacuum pump I used the upper 2 mounts off a BMW that uses them to hold the oil filter housing to the body. The third lower mount came off a shock mount. It was in our junk shelf.
    These pumps can be noisy so mounting them in rubber can help a lot. I still need to get a muffler device to install on pump's inlet.
    Brake BoosterBrake Booster

    Pump in lower background, Switch in the right and tank on the left.Pump in lower background, Switch in the right and tank on the left.
    I installed an extra one way check valve in the vacuum line coming out of the pump going towards a tee. The other check valve is on the booster.
    Finished view, ready for the inner fender.Finished view, ready for the inner fender.

    I had to adjust the booster from running too long. The switch was pulling vacuum all the way to 25 inches.
    Vacuum switchVacuum switch
    I adjusted the switch to shut off the motor at 19.5 inches. When empty, it took 55 seconds to pull to 20 inches from 0 inches of vacuum. It took 30 seconds to repull 19.5 inches after applying the brake pedal. When applying the brakes, the switch will click after the third time ( around 13 to 16 inches).

    The home made reserver tank is 9.5" long and 4" wide, made with Black ABS material.

    Reinstall left inner fender, power brakes are ready.

    FINISHED Left Front Power Brake Area with Inner fender in.FINISHED Left Front Power Brake Area with Inner fender in.