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FYI Ford, Classic Mustang Tech Discussion » trouble installing PB-5 kit, template issues » 10/16/2024 6:39 PM

Not sure if anyone will know the answer to this, if not I'll try and call tomorrow. I'm working on a 66 coupe.  

I am installing a PB-5 kit and I am ready to drill/enlarge the holes in the firewall to fit the new pedal support and the studs on the rear of the power booster.  In the instructions, it says to print out the template and verify that the width when printed is 4.625". I did that, it had to be scaled to 83%, but I printed a template and the exact size was 4.625" where indicated.  However, the center hole, which is where the bellows is supposed to come through, only measures exactly 2", where the template wants it to be 2.375".  When the template is printed so that the bottom edge measures 4.625 like the instructions say, the bolt holes do not line up with the studs on the booster and the bellows hole is too small. When I tape it to the firewall I cannot get the top two bolt holes to align like the instructions say to.  

Now, if I enlarge the size of the template so that the center hole is 2.375" like the template says, then the bolt holes line up with the studs, and the bellows fits like it should.  But the bottom width is now 5.47" which is NOT what the directions and the template says it should be.

Anybody had this issue or know which measurement I should be using?  I don't want to start cutting/drilling if I'm misunderstanding something.  
 

Board footera


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