S50 brake servo

[Jhonno]

I have found a servo which bolts in without needing the bulkhead modding or the plenum! The Hole for the pin is even the same size as an e30, however, even with an audi master cyl, it still contacts the plenum elbow albeit slightly (might be able to shave the master down a little..)

Also the issue it throws up is with the brake pull rod.. The rod which pushes on the master is shorter therefoe you have to push the pivot in to attach it, which means the brake pedal goes down.. my question is.. if i cut down and threaded a 5 series pull rod (like with Dameon's way) would that push the pedal back up? I think it will but i wanted to see if my logic is right..

Pic of the servo..

[Karan]

yeh it will but can u remove the rod from the servo?

[Jhonno]

thinkin about it again. i think it needs a shorter rod.. so a cut down e30 one.. hmm

[Jhonno]

yeh it will but can u remove the rod from the servo?

um... and use another longer one you mean?

[Jhonno]

1st post has been edited.. i mean rod that gets pushes on the master cyl, that is part of the servo is shorter where it sticks into the car

[Jhonno]

actually i have found a servo which bolts straight in.. there was enough (just) adjustment in the e30 pull rod to get the pedal back in the right place..

you just have to use an audi master cylinder and shave the corner down a little..

[Jhonno]

albeit there wont be masses of assistance, but i thought the standard setup was over assisted anyways..

[jaistanley]

It might be worth buying another, sacrificial, master cylinder to section to see how much you can safely remove from the end of it.

Trouble with the cast aluminium cylinder is that it could either be porous or have fractures through it inherantly; you don't want to thin the wall of the pressurised chamber too much! POP... screech, bang, etc etc lol.

Jai

[DanThe]

High pressure brake fluid is the next best thing to petrol in an engine bay!

[Jhonno]

ive shaved it down a little.. gonna leave it like it is for now.. Will be fine

[jmc330i]

What servo is that? Looks like a really neat fit, my servo and plenum mods are the one bit Im not totally happy with on mine.

The rubber intake boot has a metal backing, so its possible to bend it a little to clear the end of the MC. Thats what Ive done on mine as a temporary measure until I can find the cash for a carbon plenum

[Jhonno]

it only kinda 'touches' now so gonna leave it, dont want to push it

carbon plenum is on my wish list also.. maybe for the summer

[jmc330i]

I bent the rubber intake by mistake - I knelt on it by accident and didnt bother pushing it back out, just re-fitted it and found it fitted better

Its quite soft and is easy to push by hand - Once I realised, I altered my mistake a bit to make it fit better.

[Jhonno]

Doh!

Need to bend the brakes lines to fit the audi cyl now.. will do new lines eventually, but no time now, so will have to do for a min..


just remembered i need a remote reservoir of some desc.. hmm breaker it is me thinks..

[jaistanley]

So what servo is it? Looks very small but the lack of mods is tempting!

Jai

[Jhonno]

See here as to the source of the servo..

http://www.e3024v.com/board/index.php?topic=5.15

Tbh, i dont think i'll mind the lack of assistance, i had it with none at all a while back

[jaistanley]

How so? Was the servo disconnected, or removed completely?

My Golf had very little assistance, people who drove it first remarked that there must be something seriously wrong with it as it had no brakes. I was used to it and it stopped like nothing else. Meant that every time I got into a modern car I nearly put myself through the windscreen though!!

Jai

[Toby_Unna]

I think i need one of those, Mk3 Polo eh?

i moved my servo/MC towards the passenger side as much as the lengthening ability of the30 pull rod would allow... so if this servo needs a shorter rod it presumably means i could mount it even further away from the drivers' side without resorting to the e34 pull rod i have in the boot

which 3 studs does it use? that's my only concern. although if they don't break off polos there isn't really going to be a problem is there

[jaistanley]

Do we think it'd be possible to anneal the plenum around the intake boot (to hopefuly prevent it cracking) and 'gently tap' it in a bit to clear the master cylinder?

Jai

[Karan]

my s38one is cut and tig'd//// and that seems to be ok..... had a sqauare cut out and dropped in and welded a few mm

[Jhonno]

How so? Was the servo disconnected, or removed completely?

My Golf had very little assistance, people who drove it first remarked that there must be something seriously wrong with it as it had no brakes. I was used to it and it stopped like nothing else. Meant that every time I got into a modern car I nearly put myself through the windscreen though!!

Jai

disconnected..

[jmc330i]

Do we think it'd be possible to anneal the plenum around the intake boot (to hopefuly prevent it cracking) and 'gently tap' it in a bit to clear the master cylinder?

Im confused I thought it was the master cylinder touching the rubber intake boot that was the problem??

[goosiegander]

hmmm, now playing with this very same servo though it looks like i'll need to get the center console out to adjust the servo side of the bar...

[DMS]

I guess this is good starter for the LHD budget swappers.

I hope the picstures show how much room you gain by doing this. It was all relatively cheap:

-spare pedal box (15 euro's)
-sandwich plate 55mm shifted (home made)
-welding (did it myself)
-sandblasting + paint (10 euro's)
-MC audi 80 quatro coupe 1985 diameter 23mm (new at 70 euro's via ebay)
-brake booster 7 inch golf mkII (15 euro's at the breakers)
-fluid reservoir golf 3 (or type 4 year: 2000, 1.9 Tdi variant)
-brake fluid (10 euro's)

Brakes are a little harder then stock but not to hard for me. What you do miss is the initial bite at the start when braking. For reference everything is stock at the four corners aside from the pads at the front which are Ferrodo DS2500.











I'm now preparing for the next step in the swap preparation project .

[DanThe]

You cant beat moving the servo over