Just installed a new /6 with an Aussiespeed long runner intake and new Holley 2300 2bbl carb in my '87 D100. Sadly, the throttle linkage for the new carb is touching the end of the stock master cylinder. Has anyone out there replaced the stock master cylinder and booster assembly with a smaller, more compact aftermarket unit (such as the one from TuffStuff) ? If so, does it work, and were there any problems with the swap that I need to know ? I only need about an inch of clearance for the setup to work. Any other suggestions?

 

Welcome to the forum,
it would be nice to see photos of what you are working with because I would be tempted to say the lineage should be modified first. I’ve heard of K car or mini van masters getting swapped but I’m sure you would need to use a later master and then you could have problems with the pushrod length and style. It just seems like you are trading one can of worms for another.

 

Iowan,
Thanks for the welcome, and comment. I couldn't agree more. I feel like there must be an easier way to deal with the problem, rather than experimentally replace the master cylinder with an unknown component. Any constructive thoughts will be appreciated. See attached pic.

Perhaps grinding that bottom piece of the throttle linkage back a bit would help?

 

Without standing directly over it, you may be able to adapt the engine mounts by shortening the height. A shorter piece of metal would drop the engine down slightly.

 

Possibly...good idea, thanks for the input!

 

Not knowing how much of a clearance you need. Maybe placing a long bolt coming up from the frame through the motor mount while shimming or placing a spacer between the frame and mount. That should tip the engine slightly to the passenger's side.

 

You can always offset the master .5 to .75 of an inch also going with manual brakes looks like it would take care of it all.

 

Many thanks to all of you that have tried to help. I came up with the solution, should anyone have this similar problem. It wasn't a do-it-yourself kind of fix, and it wasn't the cheapest way either, but, it worked beautifully, and the problem is solved. Wilwood makes a compact master cylinder, p/n 260-14960-BK or P, depending on whether or not you prefer black anodized finish or polished aluminum finish, that was a perfect fit, and easy to install. It gave me almost 2" of throttle clearance, as the unit is only about 7" long. Of course, you could avoid the problem completely buying using the short runner Aussiespeed intake, or stick with the stock piece...boring, yet cheap!
Now to come up with a solution for the throttle cable bracket, and I'm back on the road. Thinking of fabricating a sort of elongated "z" type bracket that will bolt to the left rear bolt of the carb. We'll see. I'm always open for suggestions.