Manual brake swap+++UPDATED++w/more pics

This is what I've posted on M/R concerning my manual brake swap, thought it might help out here also.
I've been watching the manual brake post here and on other sites very closely because I'm doing the same thing. I've seen alot of the same questions keep popping up (including some by me) and I thought some pictures may help clarify things. I'm not a brake guru. I hoped to have this finished up this weekend, but been called into work a few times. So here's what I've got so far.
Here's the brake peddle from my parts car with power brakes, the upper hole (above the pushrod stud) is the hole thats needed for the manual brake pushrod to have the proper leverage.


Here's my brake peddle with the new stud pressed in (I added a bit of loctite for peace of mind) The old power brake stud could be removed, I left it.



Opening left in firewall after removing booster


Here is the adapter plate I had intended to use from a manual brake s10. Notice how the mounting holes are distorted from the bolt torque.


Instead....I'm using this aluminum adapter plate. Notice it has a integeral cup to retain the pushrod. More on that later...


The opening in the firewall need some minor trimming when a pushrod retaining cup is used, not much, took about 2-3 minutes to open up the upper portion of the opening about 1/8", I test fitted the s10 type also, that cup size is larger and would have required even more trimming.




Thats it for now. Next weekend I hope to finish up and show some pictures of the custom pushrod and Manual master bolted up. Special thanks to Malibudave1978. He's helped me get this project headed in the right direction. The guy knows his stuff!!

Re: Manual brake swap with pictures

So here is the adjustable pushrod I'm using attached to the brake pedal, the longer pushrod is from the s10 set-up, but it would need to be shortend alot to work.

Here's the factory pushrod still attached to the booster. The factory one is held captive within the booster and when the other end is attached to the brake pedal, it's a pretty solid and safe set-up that will not fall apart, when using a s-10 manual plate and cup, or one like I've shown with an attached cup, the push rod will not have an opportunity to lose contact with the master cylinder, without some type of pushrod retention, the pushrod could potentially lose contact if the pedal is over-extended.

Here's what the retention cup looks like from the interior side without the pedal assembly. (rubber boot not shown).

Here's another veiw with the pedal/pushrod and boost installed. I used a original s10 boot, however it's a bit too long and not in the best shape, I may look for something that fits a little better. Also, notice the hole above the brake light switch, it's for factory cruise control, It's not likely the push rod will fall away from the master with the retention cup, however
I plan on putting a bolt thru that hole and adjusting it to keep the pedal from over-extending (backwards) and having the pushrod fall out of the hole.

Here's a pic from the firewall side.

The kit I used came with some really nice detailed instructions, here's another picture of the parts I used (some nice stainless steel hardware was included shown in the firewall pic) thats the s10 set-up I had originally planned on using pictured next to the nice stuff.

It will be a while before I get a chance to try all this out, calipers and brake lines are on a LONG list of to do things.