Well, this is the 3rd time I’ve disassembled the pedal-box – but this time (and hopefully the last!) is to install the Whitby complete Power Brake Kit for the Wilwood Pedal-box.
This was a bit daunting at first – and the instructions admit this is the hardest part of the installation. You have to cut one of the 3/4″ tubes on the chassis to make room for the extender bar to allow the brake booster to fit properly.
I pre-assembled the booster and cleaned up the footbox panel.
That went well, but I realized the next step will be a bit harder. In order to have the brake booster connect to the Whitby brake pedal, you need a hole to fit! First was to remove the foot-box panel and make a template for drilling.
Three of the 4 holes for the booster lined up pretty well. and I had to drill out the lower passenger side through the Wilwood box. Needless to say, it’s thick metal and I stepped through several drill bits – and the forums suggested a step-bit for easier drilling. I got some cutting fluid, and a hole saw and will be working on the big opening next. Using a 2 3/4″ hole saw is the perfect size for this. Hope to update soon!
Lastly, I wanted to seal the booster to pedal-box a bit better, so I reached out to Replica Parts to get a brake booster spacer. In hindsight, this would have been a great template to use!
