FYI FORD - MustangSteve's Ford Mustang Forum
The Internet's Most Knowledgeable Classic Mustang Information
IF YOU HAVE A QUESTION ABOUT CLASSIC FORD MUSTANGS, YOU HAVE COME TO THE RIGHT PLACE!
MustangSteve has over 30 years of Mustang experience, having owned 30 of them and restored several others. With the help of other Mustangers, this site is dedicated to helping anyone wanting to restore or modify their Mustang.... THERE ARE NO DUMB QUESTIONS!!!!!
Visit MustangSteve's web site to view some of my work and find details for:
FYIFORD Contributors' PICTURES - Power Brake Retrofit Kits for 65-66 Stangs - Classic Mustang FAQ's by MustangSteve - How to wire in a Duraspark Ignition - Mustang Ride Height Pictures and Descriptions - Steel Bushings to fit Granada Spindles to Mustang Tie Rods - Visit my EBAY store MustangSteve Performance - How to Install Granada Disc Brakes MustangSteve's Disc Brake Swap Page - FYIFORD Acronyms for guide to all the acronyms used on this page - FYIFORD Important information and upcoming events

You are not logged in. Would you like to login or register?

  • Index
  •  » FYI Ford, Classic Mustang Tech Discussion
  •  » trouble installing PB-5 kit, template issues

    • 1 of 1

       

    10/16/2024 6:39 PM  #1

    assault_muffin
    Active Member

    Offline

    Registered: 8/08/2024
    Posts: 1

    trouble installing PB-5 kit, template issues

    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.  
     

    Last edited by assault_muffin (10/16/2024 6:42 PM)

     

    10/17/2024 7:43 AM  #2

    BobE
    Senior 24-7 FYI Addict

    Offline

    From: White Plains, NY
    Registered: 4/04/2013
    Posts: 2,567

    Re: trouble installing PB-5 kit, template issues

    I think your best option is to call and find out why.
    Although, I don't understand why the your computer would reduce the size to 83%.  And, while it is always good to verify dimensions, it is a little surprising to me that the installation instructions would highlight this as a 'caution' step.  Seems to indicate to me that this has been an issue previously. 

    65 Fastback, 351W, 5-speed, 4 wheel discs, 9" rear,  R&C Front End.
     

    10/17/2024 7:50 AM  #3

    mustangermike
    Administrator

    Offline

    From: Cleburne
    Registered: 4/13/2017
    Posts: 204

    Re: trouble installing PB-5 kit, template issues

    That's really odd, but not surprising.  When we print the template out to ship with the kits we have to make sure that the template is correct too.  And that's even when we print it on our printer that we normally use.  My experience, and from what I hear of other folks, is that all printers will print drawings like this differently.  I don't understand why, but that's what I have found.  I'm sorry for the confusion though.  I would take the firewall plate, the part that you're printing a template of, and just trace it in order to assure that all the holes line up properly.  That's a surefire way to guarantee that everything lines up as it should. 

    Owner of MustangSteve - 1967 Mustang Coupe 302, 2005 Mustang GT
     

    10/17/2024 9:16 AM  #4

    Nos681
    Senior 24-7 FYI Addict

    Offline

    From: Atlantic Mine, Michigan
    Registered: 7/14/2016
    Posts: 3,318

    Re: trouble installing PB-5 kit, template issues

    The center hole for the bellows does require modification.

    Definitely worth the effort…my opinion.

     

    10/17/2024 8:42 PM  #5

    MS
    Forum Originator

    Offline

    From: Canyon Lake, Texas
    Registered: 1/24/2013
    Posts: 12,162

    Re: trouble installing PB-5 kit, template issues

    The center hole is of no consequence when drilling the booster stud holes. With most brand new boosters, the 2” center hole works fine. Just be sure the studs fit first, then enlarge the center hole so you are certain the booster’s rubber bellows will not drag or be cut by the sides of the hole

    Mustangermike’s advice to trace the mounting plate is probably best/easiest practice.

    Money you enjoy wasting is NOT wasted money... unless your wife finds out.
     

     

    1 of 1

  • Index
  •  » FYI Ford, Classic Mustang Tech Discussion
  •  »  trouble installing PB-5 kit, template issues

    • Board footera


    REMEMBER!!! When posting a question about your Mustang or other Ford on this forum, BE SURE to tell us what it is, what year, engine, etc so we have enough information to go on.