I'm installing power brake booster on my '76 maverick (see this thread for more info: http://mmb.maverick.to/threads/adding-power-brakes-to-a-1974-comet.36934/). I need to enlarge the center hole to approx. 2" so the booster will sit against the firewall. What's the best way to accomplish this task? Not much room for anything like a hole saw, and you couldn't keep it aliened with the center already out. Is there an green-lee hole punch that I could use (not sure if there is room on the interior side)? I guess I could hand file it, but man that would be a long and painful route to take? Any suggestions? Thanks! Art
bolt a plate to the inside, mark the center and drill with the hole saw... just cut through the firewall...
I really don't remember how I did it....but see if anything helps you here: http://mmb.maverick.to/showthread.php?t=19107
That's a great idea Frank, that would work. Mavdog71 (Jay) also suggested using a die grinder. I don't have one of those, but I can see how that would be a handy tool to have! So either way I have some options. And thanks Craig for pointing me to your thread. Perhaps you didn't need to make the center hole any larger because you used a factory setup??
Die grinder with a carbide burr, a five minute job. If you don't have air, you can buy them in electric. Kinda like a Dremel on steroids...
The die grinder worked very well, that is a new "must have" for future tool purchases! So with the enlarged hole, the booster pulled in nice and I had enough bolt length to get the nuts on from inside, under the dash. However, it was a b!tch getting those nuts tightened up, no room, can't see, etc., etc. Finally got done after lots of grumbling, lol. However, two of the brake lines run behind the booster. I wish I would have bent down that metal flange (see pic) before the booster install. I didn’t think the booster was going to pull in that far. I also had a temp sensor cable there that got pinched a little, hope it’s ok. I think if I loosen the booster back up, I think I can slip a piece of rubber hose over the brakes lines for a cushion.
