The BTB brake booster and...
The BTB brake booster and master assembly is shown installed on the firewall of the Aqualu aluminum Scrambler tub.
Safely rolling around in an old Jeep fitted with massively oversized tires and increased vehicle power requires more than just a factory master cylinder and booster. With a 5.9L engine and oversize tires, our Project Scrambled Adventurer needed reliable safe stopping power to navigate trails and highways. We received a call from Larry Lindsey at BTB Products in Las Vegas, Nevada, about his new Master Booster combo and jumped at the chance to fit it on our custom CJ-8. BTB has been building complete Toyota and Jeep vehicles as well as manufacturing top-quality automotive parts for years.
In a nutshell, three factors are required for braking: a brake pedal for leverage, a master cylinder and power booster for hydraulic force, and disc brakes for friction. If you are running around in an old CJ without a brake booster, it's definitely something you might want to consider. The brake booster uses vacuum from the engine to multiply the force from your foot to the master cylinder, giving you considerably more braking power.
Our new hydraulic force is the master cylinder brake booster combo assembly from BTB. This new high-quality unit is made specifically for old CJs. It's a complete unit and ready to bolt in, and it's very easy to install. For CJ owners, the swap is simple: Remove the old unit, bolt in the new master booster, and connect the brake lines. But because this is a custom build, various other parts were needed to complete the job. Our stainless steel brake lines and heavy-duty brake hoses came from Quadratec. J&W Jeep Recyclers in Antelope, California, provided the brake-pedal assembly, mounting brackets, and an early-model YJ tilt steering column. The BTB kit also included a proportioning valve and pre-bent sections of tubing to connect it to the master cylinder.
As with any custom installation, the key is to remember that all the parts need to be aligned correctly for proper operation. In this case, the pedal assembly holds the steering column in place. It not only needs to be located properly for steering and driver ergonomics but also so the components meet their connection points inside the engine compartment and function properly.
 In addition to the BTB brake...  In addition to the BTB brake booster assembly, we'll also install a brake-pedal assembly and steering-column assembly from a Jeep YJ. If this unit were an upgrade to an old CJ, it would be a simple four-bolt installation, including the connection of brake lines and brake bleeding. |  We had to start by installing...  We had to start by installing the YJ steering column. The best way to begin is to measure a stock YJ and figure what the factory fitment is and then transfer it to the new vehicle (if possible). Then, measure and mark the points for mounting the top of the brake-pedal bracket assembly. These measurements were 10-9/16 inches in from the side of the tub and 5/8 inch down from the cowl. |  The inside of the Aqualu Scrambler...  The inside of the Aqualu Scrambler tub is a little different than a stock YJ, but the measurements are just about the same. The differences did not affect the installation of steering and brake components. |