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Bosch iBooster

G

Grendel

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Ah, sorry, I see what you mean now... I linked the wrong file, no, I have not used the low profile reservoir adapter.

I meant to link the dimensions CAD:

irate4x4.com

iBooster Gen 2

iBooster Gen 2, rough measurements by hand, suggested for reference use only
irate4x4.com irate4x4.com

Here's the thread that discusses them in great detail:

irate4x4.com

iBooster Electric Brake Booster

I didn't see anything on irate about the iBooster so wanted to start a thread about it now that I have some evidence of it being good for crawling. This is meant to give information and add options when it comes to braking, not to say it's better or worse than other options. Summary: I...
irate4x4.com irate4x4.com

On my CJ project, I plan to mount a 2nd gen iBooster right to the firewall and put an adjustable clevis on it to the brake pedal.


1680552176010-png.670759
 
jc_chandler

jc_chandler

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I just finished this swap on my EV-converted 8. I used a gen 2 iBooster supposedly out of a '21-23 Tesla Model S. I took measurements of the booster mounting studs and the firewall mounting holes and worked up simple brackets in CAD and sent them off to SendCutSend. The pushrod threads on the booster are metric of course (I removed the factory clevis) so I got a metric-to-imperial female adapter nut from McMaster and attached my existing pedal connector so there's some adjustability. The brake line ports on the booster are also metric so I got a pair of adapters for that too. Wiring was simple using the harness mentioned in a previous post. It's dead silent, pulls near zero power when idle and under 10A with normal braking. I can lock up the brakes but the pedal feel is softer than I was anticipating. With it off the pedal is very firm. From my online research this seems to be the nature of these things and may actually be vehicle-specific CAN-programmed. There are folks out there working on CAN controllers for these so maybe there will be something available soon that allows for easy adjustability. I did bleed the snot out of it and the bore on these is 26mm so right at 1". I'm going to take it to a local brake shop next week and have them look everything over, test the pressure at the calipers, etc, just to make sure it's optimal and safe.
 

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G

Grendel

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jc_chandler said:
I just finished this swap on my EV-converted 8. I used a gen 2 iBooster supposedly out of a '21-23 Tesla Model S. I took measurements of the booster mounting studs and the firewall mounting holes and worked up simple brackets in CAD and sent them off to SendCutSend. The pushrod threads on the booster are metric of course (I removed the factory clevis) so I got a metric-to-imperial female adapter nut from McMaster and attached my existing pedal connector so there's some adjustability. The brake line ports on the booster are also metric so I got a pair of adapters for that too. Wiring was simple using the harness mentioned in a previous post. It's dead silent, pulls near zero power when idle and under 10A with normal braking. I can lock up the brakes but the pedal feel is softer than I was anticipating. With it off the pedal is very firm. From my online research this seems to be the nature of these things and may actually be vehicle-specific CAN-programmed. There are folks out there working on CAN controllers for these so maybe there will be something available soon that allows for easy adjustability. I did bleed the snot out of it and the bore on these is 26mm so right at 1". I'm going to take it to a local brake shop next week and have them look everything over, test the pressure at the calipers, etc, just to make sure it's optimal and safe.
Click to expand...
Any chance you want to share that file? I can cut them on my plasma.
 
jc_chandler

jc_chandler

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Grendel said:
Any chance you want to share that file? I can cut them on my plasma.
Click to expand...
Happy to, what file type do you need? One thing to note is that the I did it doesn't include a relief cutout for the pushrod boot area. I had one in the design but SendCutSend would do the bends because it would apparently deform it. So I removed the relief, had them cut and bent without it, then cut that area out myself.
 
G

Grendel

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jc_chandler said:
Happy to, what file type do you need? One thing to note is that the I did it doesn't include a relief cutout for the pushrod boot area. I had one in the design but SendCutSend would do the bends because it would apparently deform it. So I removed the relief, had them cut and bent without it, then cut that area out myself.
Click to expand...
Any format would work.
If you don't mind, I'd like to put them on the Irate4x4.com file share?
 
4x4 EVC

4x4 EVC

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Grendel said:
https://irate4x4.com/resources/ibooster-gen-2.53/

If you needed dimensions.

There's also an adapter that I've cut and used.
Click to expand...
Sorry to be so late to the party, I too didn't know all the drama surrounding Pirate but thanks for posting the info elsewhere - BUT, using your link, there is not picture on that page - could it be due to my recent registration to that forum, you know, restricted till I do 50 push-ups and spin around 32 times or something.

If you could, do you have your instill pictures, I'm VERY interested in putting it in my CJ-EVC (my build: https://www.jeepforum.com/threads/jeep-cj-7-ev-conversion.4455457/ ) to be a potential replacement for those customers that want Power Brakes.
 
bigwalton

bigwalton

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4x4 EVC said:
Sorry to be so late to the party, I too didn't know all the drama surrounding Pirate but thanks for posting the info elsewhere - BUT, using your link, there is not picture on that page - could it be due to my recent registration to that forum, you know, restricted till I do 50 push-ups and spin around 32 times or something.

If you could, do you have your instill pictures, I'm VERY interested in putting it in my CJ-EVC (my build: https://www.jeepforum.com/threads/jeep-cj-7-ev-conversion.4455457/ ) to be a potential replacement for those customers that want Power Brakes.
Click to expand...
Damn. I’d love to read that thread. But I just can’t take jeepforum anymore. Good lord, it’s like the ads have ads in them 😳
 
jc_chandler

jc_chandler

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CO
4x4 EVC said:
Sorry to be so late to the party, I too didn't know all the drama surrounding Pirate but thanks for posting the info elsewhere - BUT, using your link, there is not picture on that page - could it be due to my recent registration to that forum, you know, restricted till I do 50 push-ups and spin around 32 times or something.

If you could, do you have your instill pictures, I'm VERY interested in putting it in my CJ-EVC (my build: https://www.jeepforum.com/threads/jeep-cj-7-ev-conversion.4455457/ ) to be a potential replacement for those customers that want Power Brakes.
Click to expand...
There are two versions of CAD files linked in my post above, are those what you're after? Also, just a heads up, I mentioned in another post that I did cut out a relief area in the brackets (pictured below) to allow for the booster pushrod boot b/c SendCutSend didn't like it (something about bending with that area cut out would have deformed it).
 

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jc_chandler

jc_chandler

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I should also note that those brackets work for the specific iBooster I got (21+ Model S). I can't speak to the mounting dimensions of iBoosters from other makes/models.
 
G

Grendel

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4x4 EVC said:
Sorry to be so late to the party, I too didn't know all the drama surrounding Pirate but thanks for posting the info elsewhere - BUT, using your link, there is not picture on that page - could it be due to my recent registration to that forum, you know, restricted till I do 50 push-ups and spin around 32 times or something.

If you could, do you have your instill pictures, I'm VERY interested in putting it in my CJ-EVC (my build: https://www.jeepforum.com/threads/jeep-cj-7-ev-conversion.4455457/ ) to be a potential replacement for those customers that want Power Brakes.
Click to expand...
It's a CAD file you can download:

 
4x4 EVC

4x4 EVC

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Chatsworth
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bigwalton said:
Damn. I’d love to read that thread. But I just can’t take jeepforum anymore. Good lord, it’s like the ads have ads in them 😳
Click to expand...
Do they, I don't get them, maybe it's because I'm registered, don't know. BUT, hands down, they have the deepest bench of knowledge over there.

For me, I struggle with some of the, mmm, shall we call them Die-hards that feel comfortable voicing their otherwise NON-Jeep opinions openly.

Whatever, the Mods are kings and they stay pretty vigilant over there.

Come on, be brave Big Guy, suck it up and just deal with the ads upon ads - it's a good read, I promise....

- Patrick
 
4x4 EVC

4x4 EVC

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City
Chatsworth
State
CA
jc_chandler said:
There are two versions of CAD files linked in my post above, are those what you're after? Also, just a heads up, I mentioned in another post that I did cut out a relief area in the brackets (pictured below) to allow for the booster pushrod boot b/c SendCutSend didn't like it (something about bending with that area cut out would have deformed it).
Click to expand...
That mounting flange CAD file is cool, thanks!

I'll be most of this is academic until I have pump in hand - from what I've read, Gen 2 is the way to go.

I'm pretty sharp, I can figure out the mounting, I was so happy to see there is a starting place using that stock Booster mounting bracket - that help.

Did you have to do any work on the plunger?
 
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