iBooster

To my recollection the GEN1 was more compact than the GEN2. I started playing around the orientation to see how close I could get the input rod when it was parallel with the floor. I found the best position was when the ECU was rotated to a 35-degree angle as shown below. In this orientation withe the input rod is only 2.25” above the floor when parallel.

When the pedals are on top of the 1/8” thick bracket, the brake pedal rod end is 2.43” above the floor. This means that it’s above so we can get a GEN1’s input rod to be perfectly level with the floor (i.e., the exact angle as the original master cylinders). To achieve this, the following must be done:

• The mounting plate with the four protruding bolt must be removed.

• The master cylinder is rotated 180 degrees. This tilts the reservior feeds upwards rather than downwards (see the middle picture)

I need to validate the following:

• Confirm that the clutch master cylinder clears the iBooster. My guess is that a Tilton short one will need to be used.

• Confirm that there is enough front-to-back room in the foot box.

• Confirm that the electrical connector will clear the floor. My guess is that it will need to be ground.

• Confirm that the iBooster can be used in this orientation. I believe that it can.

Assuming that all of the above is confirmed, do you think that it will solve the problem? Specifically, that there is no need to modify the brake pedal.

I’m going to investigate if I can use a GEN1 or GEN2 iBooster made by Bosch to add power brakes. Useful links:

• Bosch iBooster

• iBooster donor vehicles - EVcreate

• iBooster Controller ECU - SGH Innovations

• (6) Inside Tesla's Brake Booster (And How To Use It On Any Car) - YouTube

• iBooster Bench Test Apr 15th 2016b - Bing video

Dimension             GEN1    GEN2
Length                     TBD     9.6"
Overall Width         6.1”    7.5"
Center to Top         4.9"    3.9"
Center to Bottom   3.5"    6.3"

• Balance bar threads 5/16”-24

Specifications:

• Travel: 40 mm (1.57”)

• Clevis has M10x1.5 mm thread (0.394”)

• Clevis Interior: 0.362”
  
  

Potential Clevis Connectors:

TYPE SIZE DECIMAL WIDTH DELTA
Rod End M8 0.315” 0.472” Won’t Fit
Rod End 5/16” 0.313” 0.438” Won’t Fit
Rod End Bolt M8 0.315” 0.315” Small 0.047”
Rod End Bolt 5/16” 0.313” 0.313” Small 0.049”
Rod End Bolt 3/8” 0.375” 0.375” Large 0.013”