if you can fit vacuum booster, then I'd try that first. I didn't have room for a vacuum booster. Was going to have to do remote hydroboost, and then decided I'd try iBooster.

 

I haven't updated here in a while. The short week before Thanksgiving I was at Rugged Mountain Ranch in Oklahoma when my buggy lifted a fuel rail when a nutsert in the plastic intake pulled out. This caused a fire that burned my wiring harness and destroyed my seats. As part of project creep over the winter, I decided I would upgrade to an iBooster since I was rewiring anyway.

The iBooster uses a 26mm master cylinder, which would have been overwhelmed with my stock front 2007 d60 calipers and rear 1/2-ton chevy calipers. So I started off thinking I'd use some junkyard 2009 ford flex calipers that gave me a reasonable hydraulic ratio.

I started with the rear calipers and got them to fit, but I couldn't make it work on the front without machining the knuckles, and I didn't want to go down that path. So I did some research and ended up with Howe 33658 calipers up front that are the same casting size as K10 calipers but with 2.625" pistons instead of 2.94 or 3.15 pistons. This matches up with the flex calipers.

On the rear I ended up reusing the 2003 Yukon XL 3/4-ton rear rotors instead of going to 1999 E350 rear rotors. They have the right bore for 14-bolt hubs and are a 12.99" diameter instead of 12.83". The flex pads fit perfectly on the yukon rotors.

front calipers using original mounting provisions on brackets that I made. The front uses 1999 E350 rotors with the center bore opened up.

 

To fit the iBooster, I had to make an offset mount. The brake pedal is in the same location as when I had manual brakes. I moved the brake shut off valves from right by the master in my old setup to something I could easily reach when belted in.

This weekend I'm headed to Good Evening Ranch in West Virginia, so it'll be a good test of how I like the iBooster. It feels good on my test laps around the block.

 

Since I had a bunch of rewiring to do, I decided to move the ECM from under my switch panel to the B-pillar firewall. The terminator wiring harness was perfect length to do this, and prevented me from having to wrap it up under the hood. So I built a new center console and the box at the back cover the ECM to protect it from the elements.

The old center console was thrown together with a plan to be temporary, but was good enough to not mess with. I'm pretty happy with the new version that extends the whole tunnel and hides wiring and plumbing.

 

Looks fantastic!!!

 

Nice work! Glad the fire did not cause more damage! The ibooster looks like a nice unit and much easier then running hydroboost. Very compact as well.

 

Back from the weekend, and 100% happy with the brakes on the trail.

End of the day Saturday I tested it by driving off a big ledge. Old brakes I'd struggle to hold it back, needed lots of leg to hold. Now it's moderate pressure and it's got more holding pressure than anything I've driven. I was able to creep down the ledge with great control. Very happy.

 

Some pics I nabbed form facespace and irate4x4.