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Old 10-09-2020, 08:23 AM   #1
SkeTchy-MechAniC
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Thumbs up Sharing Volvo 240 tiny brake booster adapter plate

I'll be finishing this swap the weekend and thought i'd share this drawing with you guys. It's true scale, So when printed it can be used as a template. And when doing this swap you'd have to bend the taps a bit to fit the with of the pedal. I just bent them open, placed a 12,5 mm drill in between and bent them straight again in the vise. The pin that goes thru the paddle is slightly thicker on the suzuki one, you could drill the hole in the pedal to 10mm, Or use the volvo one with two adapter bushings ( Inner D8 Outer D10 With 4.2)

https://www.dropbox.com/s/l6lavm08vo...plate.pdf?dl=0





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Old 10-09-2020, 12:19 PM   #2
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Nice! What's the force multiplication on this booster?
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Old 10-09-2020, 11:07 PM   #3
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what yr and model of suzuki? Just got threw removing my stock one today. Looking to order a smaller one.
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Old 10-10-2020, 08:09 AM   #4
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Old 10-11-2020, 03:39 AM   #5
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Might be this found on another post here.
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Old 10-11-2020, 04:36 AM   #6
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Quote:
Originally Posted by carver View Post
Might be this found on another post here.
You're right! that's the one.

The volvo master cylinder has a 22mm bore vs the 20mm of the suzuki. roughly 10% less surface area, slightly more pedal travel but i dont think it's going to be a problem, Pedal feels good.
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Old 10-11-2020, 08:04 AM   #7
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Were you able to use the stock master cylinder?
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Old 10-11-2020, 08:29 AM   #8
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This is the master cylinder i used:

https://www.autopartsonline.nl/remsl...RoCceoQAvD_BwE

I just see that its 20,6mm, So only 1.4mm difference with the stock volvo mc. Note that this is for a newer swift than the booster comes of, That's because the old ones are hard to find new mc's for. They are the same as the older ones except for bolt spacing. I had to drill two extra holes to make it fit.

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Old 10-11-2020, 12:41 PM   #9
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Default brake boster

Hi, Nice set up. Ive been working with a different type of brakes , but is been a pain trying to get the mc to hold pressure. I changed the booster forma toyota corolla nd the nc form a camry 1 inch bore non abs. Front calipers are 2 piston subaru wrx with nissan altima brackets and infinity rotors redrilled and grinded down around the circumference for proper fiting. Ive been trying to make the mc to hold pressure with no luck. Ive bled the system twice and once i hold pressure , the pedal stays up Once I let go it sinks. So for now im in a stand still cause im rewelding the oil pan. Once thats done , i gotta see whats up with the brakes .Good luck wuith yours
DZ
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Old 10-13-2020, 05:37 PM   #10
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What thickness is the plate?? Thanks for the thread!
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Old 10-19-2020, 02:42 AM   #11
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Quote:
Originally Posted by cosbySweater View Post
What thickness is the plate?? Thanks for the thread!
I made mine out of 5mm thick aluminum.
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