Project: 1966 Stepside LWB

[b2948kevin]

Here I got the calipers and hoses mounted up to the new discs. It took a few tries to make sure that I got everything lined up correctly, but everything fit.

[b2948kevin]

Next up, I spent some time getting power steering installed. I did this pretty quickly, and someone more equipped than me could probably do it in 3/4 a day. This took me about a day and a half, but it wasn't nearly as bad as I thought it was going to be.

I bought CaptainFab's power steering adapter plate, which is super quality. Seriously, did a machine make those welds? I've worked with professional welders who couldn't run puddles like these. The captain's kit comes with instructions and a template which is really helpful.

[b2948kevin]

Next, I dropped the old power steering unit off. I cut the steering rod 1 3/4" after the existing flange, per the included instructions, just so I didn't have to fight with it while it was still installed. Remember to keep a ball joint separator (pickle fork) around to separate the pitman arm from the steering rack.

You can see in a couple of these pictures that I put new tie rod ends on. The old ones were pretty nasty.

[b2948kevin]

I used the template that was included in the kit to mark where I was going to drill my holes for the new power steering box. I cut out the holes where the existing power steering box was mounted so that I could match the template up exactly where I needed and center punch the new hole locations. I also wire brushed the whole area and used some self etching primer to cover up the bare metal.

For one of the holes, it overlaps an existing hole by so much that I couldn't drill it. I used a round file to elongate the original to the point where I could get the bolts through where they needed to be. The kit comes with all grade 8 hardware to cinch everything down super tight.

[b2948kevin]

I bought a PS box from a junkyard which was pretty dirty, so I took it down to the self-serve car wash and power washed it. It came out pretty dang good.

I started pulling off all the stuff that I didn't need from the new PS box, and I used my helper to do some of the heavy lifting

[b2948kevin]

Back to the frame, I fitted the new adapter plate, flange and the PS box up. Everything seemed to fit right up where it needed to.

[b2948kevin]

Some more pictures of fitting everything up, and the quality of welds here. The pitman arm that was on the new PS box was in the correct position, so I didn't even have to mess with pulling it off. I was pretty happy about that.

When I bought my engine, it came with a power steering pump and all of the brackets. I don't have pictures of this part, but I put those all back on and put the PS lines on. Everything fired right up, and after some bleeding, I had a really solid PS system. Also, I put a grade 8 bolt through the steering rod to hold the new flange on. I will have it welded up in the near future, but I couldn't wait to try this out. I can steer with one finger now, and it's great!

Overall, this is one of the best upgrades I have done. I definitely recommend that everyone do this if they have even the slightest urge.

[b2948kevin]

Back to the disc brakes, here are some pictures of the brake booster rods that I had welded together. I really need to break down and just buy a welder, but I haven't done it yet.

I extended this by 3.75" which put the rod, at full rest, exactly where the bolt hole is on the pedal.

**Question - Do I need to pre-load the brake booster at all? In other words, should I have made the rod extra long to put a pre-load on the booster/MC?

[b2948kevin]

I fitted the brake booster on, connected the linkage, installed the MC and new brake lines, and gravity bled all of the lines. I fired everything up and I have front discs now!

So, when I push on the pedal, I was able to push it all of the way to the floor, so I spent another couple evening bleeding and re-bleeding the brake lines. The pedal got a little stiffer, but I am still able to push the pedal all the way to the floor when I really stomp on it. With the motor off, the pedal is really stiff and I am not able to put it all of the way to the floor, but with the booster's help, I still can.

I took it down the street for a test drive (with one hand on the E-brake), and I am able to lock up the tires at about 2/3 pedal, so I have good stopping power, but I am still not comfortable being able to push the pedal to the floor. Any ideas?

[b2948kevin]

After I took the truck around the block, I grabbed my helpers (the ones who can walk) and we brought it out to more level ground in the cul-de-sac to get some pictures of the current stance.

[LostMy65]

Originally Posted by b2948kevin

I used the template that was included in the kit to mark where I was going to drill my holes for the new power steering box. I cut out the holes where the existing power steering box was mounted so that I could match the template up exactly where I needed and center punch the new hole locations. I also wire brushed the whole area and used some self etching primer to cover up the bare metal.

For one of the holes, it overlaps an existing hole by so much that I couldn't drill it. I used a round file to elongate the original to the point where I could get the bolts through where they needed to be. The kit comes with all grade 8 hardware to cinch everything down super tight.

I'm glad you went with Captain's kit.
He helps out so much in these forums.

[b2948kevin]

Originally Posted by LostMy65

I'm glad you went with Captain's kit.
He helps out so much in these forums.

Yep, I could not agree more. I didnt even consider another kit, and I am glad I didn't. The fit and quality is really good!
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[Captainfab]

I'm glad the PS and PB install went well for you Kevin. Also thanks for posting the pics of your progress, and for the compliments.

As for the brake issue, you might try bleeding all 4 corners once more. You also might try adjusting the pushrod between the pedal and booster out just a little and see if that helps.

[McMurphy]

Kevin that is just awesome!!
I installed my PS pump this weekend too...coincidence is a funny thing LOL.
Looks like your helpers get to enjoy your truck almost as much as you do !!

Good times, those are photos that both those children will cherish later in life for sure!
Looking real good man, real good !!

[b2948kevin]

Originally Posted by Captainfab

As for the brake issue, you might try bleeding all 4 corners once more. You also might try adjusting the pushrod between the pedal and booster out just a little and see if that helps.

Thanks Captain, I think that's going to be my next item to try. I've already bled the brakes out 3 times, but I may as well go another if it gives me better brakes. I wonder if I moved the brake rod out a little (or a lot), if it would allow for more travel, and thus give more pressure, and a better brake feel.

Originally Posted by McMurphy

I installed my PS pump this weekend too...coincidence is a funny thing LOL.

Good times, those are photos that both those children will cherish later in life for sure!

Thanks again for stopping in, McMurphy! Yep, the kids love to ride around in "Mater" when they get a chance. Glad you got your PS in there. It makes a huge difference, and it was one job that was easier than I thought it would be.

I am in Dublin on business travel right now, so unfortunately all I can do is look at threads on here for the next couple of weeks.

[McMurphy]

Originally Posted by b2948kevin

Thanks Captain, I think that's going to be my next item to try. I've already bled the brakes out 3 times, but I may as well go another if it gives me better brakes. I wonder if I moved the brake rod out a little (or a lot), if it would allow for more travel, and thus give more pressure, and a better brake feel.



Thanks again for stopping in, McMurphy! Yep, the kids love to ride around in "Mater" when they get a chance. Glad you got your PS in there. It makes a huge difference, and it was one job that was easier than I thought it would be.

I am in Dublin on business travel right now, so unfortunately all I can do is look at threads on here for the next couple of weeks.

I used Captain Fabs plate too, and you are right it was one of the easiest things I have done to the truck so far!! Enjoy Dublin .... especially if you are in the Ireland one .... LOL

[b2948kevin]

Haha, thanks! I am in Ireland. Back home to Bellevue, WA mid-month.

[b2948kevin]

Man, I've been looking at some of the work that is done on some of the build threads here. When I started this project, I didn't even think of pulling the cab off and blasting the frame, etc. I was so focused on just getting my truck drivable. Now I am thinking that I may do this down the line when I get a lot of the upgrades in that I want, and I have a little more room that I can work with. I also really like the 55-59 body styles, so I may pick one of those up as well. See what you guys are making me do?

[LostMy65]

Originally Posted by Captainfab

As for the brake issue, you might try bleeding all 4 corners once more. You also might try adjusting the pushrod between the pedal and booster out just a little and see if that helps.

Originally Posted by b2948kevin

Thanks Captain, I think that's going to be my next item to try. I've already bled the brakes out 3 times, but I may as well go another if it gives me better brakes. I wonder if I moved the brake rod out a little (or a lot), if it would allow for more travel, and thus give more pressure, and a better brake feel.

Did you ever get your brakes worked out.
Did adjusting the rod as Captainfab suggested help?
Posted via Mobile Device

[CRGRS 66]

Originally Posted by LostMy65

Did you ever get your brakes worked out.
Did adjusting the rod as Captainfab suggested help?
Posted via Mobile Device

x2

[Nopocustoms]

I built my own bracket, and mounted the stock 77 burb booster and MC on my 66 - it all came from the Burb and I have the same Issue - they work but can be pushed all the way to the floor, I have just enough slack so I don't wnat to lengthen the rod and open the MC.

I am going to drill a new hole below the facotry hole - it should give more travel for the same mount of push - Just like the old Nova and Camaros of the 60s 70s they had 2 holes, one for manual brakes one for power - I will post my results here and on my build

[b2948kevin]

Hey guys, just wanted to let you know that I have the brakes working just fine. I just had to adjust the stud out and now I have great braking pressure. Bleeding like 6 more times may have had something to do with it also . I now skid to a stop anytime I want to. I also took some time to readjust the rear drums and ensure that they're engaging fully, so brake problems are no more. I have learned a ton!

Thanks Captain again for the sage advice.

[b2948kevin]

It's with a heavy heart that I am announcing that I am selling my truck. I have put a ton of work into it and have learned even more, but some things have changed and I am looking to part with it.

Don't be sad, this is not goodbye. I will do another in the not too distant future, and I am sure I will be back begging for more advice at that time

Please PM me if you have advice regarding how I should go about selling this.

[LostMy65]

Originally Posted by b2948kevin

Hey guys, just wanted to let you know that I have the brakes working just fine. I just had to adjust the stud out and now I have great braking pressure...clip...

I struggled with my brakes exactly as you.

The solution was also found exactly like yours.

I also adjusted the rod (stud) to engage the booster sooner.

I honestly think all the bleeding I did just wasted a bunch of fluid.

oh well,
All is good now.

[CRGRS 66]

sorry to hear that you have to part with your truck, I wish you the best, and hope to see you hang around

P.S. I am out in the garage tomorrow morning to start stripping off the front suspension, I thank you again for posting your experience, that helped me a lot with deciding to take the leap with my front suspension.