So another project during this off season was to do something better with my brake booster. I took both the newly purchased "rebuilt" unit, and my old failed original boosters apart and reassembled one unit using the best parts from the two, plus a couple new parts I made to replace some rusty bits. Here's the final unit. Reassembled, painted, and ready to put back in the car:
Some of the internal parts were really crappy, so I made some stainless replacements. I used stainless steel for everything with the exception of the threaded output shaft tip. I reused the original tip because it's hardened and I didn't feel like dealing with the heat treating. Besides, it doesn't ride against the vacuum seal, so even if it's not perfect, it doesn't affect operation. Here's what I made:
Here's a pic of the smooth stainless output shaft sticking through the vacuum seal. This has GOT to seal better than the rusty crusty versions I had from both the boosters. My idle will thank me:
As a bonus... My PO had painted the booster that came with the car, and I found the original sticker hiding under a thick coat of paint. Thankfully the paint didn't stick too well to the plastic sticker, and I was able to chip most of it off. It's not perfect, but it looks "appropriate" for the rest of the car. I haven't put it back on yet. Anyone have a good reference pic showing the location of where the sticker should go?