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Giving it a Jolt

Curious if you've made any headway on the iBooster install? I just picked one up off eBay b/c the Volvo steering pump isn't cutting it for both the brakes and steering rack, especially because I had to mount the pump well below the hydraulic booster in the fender well. The pump is pulling 80A+ consistently and overloading the power wire and breaker to it. Figure it's better to keep the brake and steering separate.
 
Not yet, I plan to tackle it over the winter. Too busy building a barn.
 
Took me too long but finally got the wiring done, the custom brake lines installed and the brakes bled. Took it for a spin and locked up all 4 tires (pretty much) just backing out of the driveway. Definitely a light touch and massive stopping power... Will send pictures in a bit but not much change from what you see above. Its nice not to have the rattle and hum of the vacuum pump.
 
timo439 said:
Started getting the iBooster installed. Lots of back and forth and more to do but this is how it looks. Not hooked up yet.

View attachment 112748
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I love this version of a Jeep EVC project!

Can you give us an details about how you fit that iBooster into your system - mounting specifically and how to change the plunger to match the peddle.

Also, wiring would be GREAT.

I'm working on a CJ-7 version (here: https://www.jeepforum.com/threads/jeep-cj-7-ev-conversion.4455457/) and the power brakes are an issue that would be amazing to have an electric version of like using the Volvo PS pump.

Thanks - Patrick
 
4x4 EVC said:
I love this version of a Jeep EVC project!

Can you give us an details about how you fit that iBooster into your system - mounting specifically and how to change the plunger to match the peddle.

Also, wiring would be GREAT.

I'm working on a CJ-7 version (here: https://www.jeepforum.com/threads/jeep-cj-7-ev-conversion.4455457/) and the power brakes are an issue that would be amazing to have an electric version of like using the Volvo PS pump.

Thanks - Patrick
Click to expand...

I'll chime in with my experience installing an iBooster in my Scrambler (also been following your thread on jeepforum, great stuff!). I followed a lot of the good info here. To get the iBooster plunger to connect with the brake pedal post I took off the iBooster's factory clevis style rod end and replaced it with a metric-to-imperial female thread adapter and subsequent rod end bolt, both of which I got from McMaster. For firewall mounting I had hoped to do what Timo did and simply modify an aftermarket booster mounting bracket assembly, but I needed to mount the booster closer to the firewall due to clearance issues, so I fabricated (via CAD and SendCutSend) some basic brackets using the booster mounting dimensions and the firewall mounting dimensions. For wiring, I used a prebuilt harness from here. I'm sure I could have built that harness for way cheaper but the time savings was worth it for me.
1722010933270.png1722010982405.png
 
jc_chandler said:
I'll chime in with my experience installing an iBooster in my Scrambler (also been following your thread on jeepforum, great stuff!). I followed a lot of the good info here. To get the iBooster plunger to connect with the brake pedal post I took off the iBooster's factory clevis style rod end and replaced it with a metric-to-imperial female thread adapter and subsequent rod end bolt, both of which I got from McMaster. For firewall mounting I had hoped to do what Timo did and simply modify an aftermarket booster mounting bracket assembly, but I needed to mount the booster closer to the firewall due to clearance issues, so I fabricated (via CAD and SendCutSend) some basic brackets using the booster mounting dimensions and the firewall mounting dimensions. For wiring, I used a prebuilt harness from here. I'm sure I could have built that harness for way cheaper but the time savings was worth it for me.
View attachment 114459View attachment 114460
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Hi JC - this is GREAT - thanks!!

Do you see how he mounted his to the firewall, using this bracket:
1722043321702.png

I think that's the same bracket as every P/S adapter for all Jeeps in this series:

I'm trying to attach the image here but this forum is being buggy at the moment...
 
4x4 EVC said:
Hi JC - this is GREAT - thanks!!

Do you see how he mounted his to the firewall, using this bracket:
View attachment 114462

I think that's the same bracket as every P/S adapter for all Jeeps in this series:

I'm trying to attach the image here but this forum is being buggy at the moment...
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This one:
1722043496410.png

I think it adds a bit leverage to the system. Might be unnecessary (and dangerous) and I should do as you suggest and go with a single rod.
 
4x4 EVC said:
This one:


I think it adds a bit leverage to the system. Might be unnecessary (and dangerous) and I should do as you suggest and go with a single rod.
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That is the standard bracket that he modified to work with the iBooster. It would add a bit more leverage but I don't think it would be dangerous, though I don't have any numbers to back up that claim. I simply couldn't use that bracket b/c of a lack of clearance. I wanted to since it would have made the install a lot easier.
 
jc_chandler said:
That is the standard bracket that he modified to work with the iBooster. It would add a bit more leverage but I don't think it would be dangerous, though I don't have any numbers to back up that claim. I simply couldn't use that bracket b/c of a lack of clearance. I wanted to since it would have made the install a lot easier.
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Correct, that is the bracket I used. I would need to understand what is meant by "leverage". Activating the booster takes significantly less pressure so I have zero concern about durability. I also created an aluminum spacer to accommodate for the different pushrod lengths. So far so good.
 
timo439 said:
Correct, that is the bracket I used. I would need to understand what is meant by "leverage". Activating the booster takes significantly less pressure so I have zero concern about durability. I also created an aluminum spacer to accommodate for the different pushrod lengths. So far so good.
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That's great - pictures PLEASE!

What I meant by 'leverage' was the design of the adapter, it's not just a spacer, it has a function of increasing the force at the pump. I didn't understand that before, that's all.

Question: why spacers for different plungers? Am I missing something, doesn't the length of the plunger in relation to the pump a fixed length? Or are you doing it for some other reason?
 
jc_chandler said:
That is the standard bracket that he modified to work with the iBooster. It would add a bit more leverage but I don't think it would be dangerous, though I don't have any numbers to back up that claim. I simply couldn't use that bracket b/c of a lack of clearance. I wanted to since it would have made the install a lot easier.
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JC, did we meet at SEMA two years ago, in the booth with your Scrambler? It was the Electrified GT booth (now owned by Tremec!!!!)

Can you send us pictures, or for the ill-informed (me), point me to your build thread on here? I'm installing against the stock firewall and can make any adjustments for spacing I need to at this point.

- Patrick
 
4x4 EVC said:
JC, did we meet at SEMA two years ago, in the booth with your Scrambler? It was the Electrified GT booth (now owned by Tremec!!!!)

Can you send us pictures, or for the ill-informed (me), point me to your build thread on here? I'm installing against the stock firewall and can make any adjustments for spacing I need to at this point.

- Patrick
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Sounds like we did! ElectricGT (now Tremec ElectricGT) brought the Jeep out to be in their booth, very cool experience, though it was far from running and driving back then. Heck, I'm still working out kinks, with their support, in the AEM VCU300 and BMS programming. Looks like you found the iBooster thread on here, which is really the only place I've posted about it other than this thread. I started a build thread long ago but I'm terrible keeping up stuff like that. I did use that irate thread for guidance as well as the SuperFastMatt video that's linked to there. I'll try and snap a few pictures this week after work.
 
jc_chandler said:
Sounds like we did! ElectricGT (now Tremec ElectricGT) brought the Jeep out to be in their booth, very cool experience, though it was far from running and driving back then. Heck, I'm still working out kinks, with their support, in the AEM VCU300 and BMS programming. Looks like you found the iBooster thread on here, which is really the only place I've posted about it other than this thread. I started a build thread long ago but I'm terrible keeping up stuff like that. I did use that irate thread for guidance as well as the SuperFastMatt video that's linked to there. I'll try and snap a few pictures this week after work.
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I thought so, wow, what a great restoration you had!!

Remember when we talked, I told you it would take a LOT of work to finish up - these things are NOT easy. Did you see my first test drives on mine? I hope you're is or get stable because I LOVE, LOVE, LOVE driving mine and I'm only on day 4 of having it finally drive.

Not kidding, this is the best thing EVER!!!

Lastly, yes, going to every one of the forums and such you mention - really perfect recourses - THANKS!

If you can, more pictures of the booster installed would be nice, any any measurements from Firewall to end of iBooster could be great also. I've got a different layout then the way Tremee ElectricGT layed out yours, I preserved as much space between the Firewall and the Tech Box so I could deal with stuff like this - PS, Power Brakes, Heater Motor, AC lines (if I ever do that...).

My engine bay looks like this:
1722317127683.png

I think I have the Length but I'll obviously have to trim the Tech Box a bit for those customers that want a Power Brake Booster.

Thanks!
 
designerRob said:
That's awesome! What kind of range do you think you have?
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THANKS - it's easily the most general fun I've ever had in my 44.5 years of owning Jeeps. I say 'general'' because I haven't taken it fully off road, crossed any streams, back trails, stuff like that. Yet...

GREAT question - it's not super easy to figure out yet. I was shooting for 120 - 7 Tesla battery modules should yield you about 20 miles per module.

What I'm seeing right now, early days, is around 80-90 PRE-Regen.

Regen should give me a 20% bump.

I'm in Speed Mode also so I get tons of power but not as efficient.

If I use this method: Start with a fully charged Pack, Go from Point A to Point B, record the miles, do a full charge (again), take the kWh (juice added back to the battery) and divide that by the miles, I get right at 3.5 mi. per kWh.

So, back to math, 7 Tesla battery modules (5.3kWh / modules = 37.1 total kWh) 3.5 miles per kWh X 37.1 = 129.85 mi. range. (before regen).

I seriously doubt I'll ever get 130 miles range but I would be tickled pink to get 100 miles range - like, that would be a homerun.

Again, all my calculations are pre-regen, so, bonuses are coming...
 
bigwalton said:
That video is wild @4x4 EVC.
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Last night, randomly, 11:40 at night, I grabbed a cap, walked from my back door to my Jeep shop, got into my Jeep, turned the key to ON and drove silently into the night, time slipping away, taking in the city, hearing things I would never notice otherwise.

All the mischief and exposure of an open Jeep on the road with none of the normal anxiety of all the little things we stress about when we get in our rigs - will this break, is that noise the thing I fixed last week, if I sit too long, will my temp shoot up, why is it all of a sudden idling strange, etc., etc., etc.

Replaced by the woosh of rushing air has I accelerate to a-bit-too-fast and no time.

I love it more then I ever thought possible.

- Patrick
 
LOL. you're not thinking hard enough if you don't still have those worries over what's left in the Jeep. If it were me, I'd be watching for the electrical fire caused by something I did wrong, just like with an ICE :rotfl:

The silence is freaking weird though and I get what you're saying
 
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