Anyone ever made a power brake booster bracket out of aluminum?

[SnS C10]

Going to attempt this tomorrow at work. I am a machinist so i figured what the heck might as well try it. If it doesn't workout, for sure I'm buying one from captainfab. His makes more sense anyway, dollar and speed wise, but I like to make design and machine things. I'll let you know how it turns out

[cv65]

seen this on ebay http://www.ebay.com/itm/1960-1966-Ch...EKbSkvoE0B8xrQ

[SnS C10]

Yea that's not going to work. Mine will be a solid chunk of 6061-t6 and be machined into a very nice piece. I'll post pictures when complete

[Juice63]

Originally Posted by cv65

seen this on ebay http://www.ebay.com/itm/1960-1966-Ch...EKbSkvoE0B8xrQ

I purchased this item. Great quality and got it fast and at a good price. When it is on I will post pix.

[SnS C10]

Couple pictures. Mine piece will be a fully enclosed unit. Won't be able to see any hardware. It will look like a solid aluminum block and that's its. Almost done with it, just need to make a few adjustments.

[SnS C10]

I ended up modifying the bracket quite a bit more. I'm happy with the end result and it should look good on the truck. Here are a few pictures

[slepysal]

very nice !!

[siggyfreud]

As someone who is just getting into machining and routing that piece looks like it was a bit complicated. Maybe not from a design perspective, but looks like you may have had to flip it a few times to mill all the sides, unless you have a $$$ machine that will turn it all for you.

[SnS C10]

SiggyFreud your correct. Mill both ends for parallelism. Do all the detail work like counterbores and bolt hole locations. Mill the profile. Turn part on end at 45 degree angle, 4 times for clearance for the bracket to booster bolts. If I had an indexer, much faster. I could machine this parts in about 25 minutes if I refined the process a bit

[siggyfreud]

Yeah sounds like a pain. I'm still learning/refining my process to do 2-sided cutting since I don't have a good edge finder. Right now I'm zero'ing my work at dead center, and just using measurements to find that center. Then I cut/drill through into some spoil material at two locations to set an index and use a bit or dowel as my location tool. Very much a pain in the butt.

I definitely had some crazy idea that this would all be much easier to jump into than it is haha.

[SnS C10]

No problem captainfab. And just as I stated, one of the machines is down.