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1968 Ford F-100 - The Bumpside Build Off -Tech

1968 Ford F100
Depending on where you mount... 
   
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1968 Ford F100
Depending on where you mount your master, you may need to reinforce the area due to the amount of force it takes to push in the clutch pedal. The firewall on the F-100 was braced around the brake master for this reason, but there wasn't anything but sheetmetal where I mounted the clutch master. So I marked the general size and shape of the doubler plate that I'll weld to the firewall for strength.
1968 Ford F100
First, making sure the truck... 
   
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1968 Ford F100
First, making sure the truck sat level side to side and at ride height, I leveled the master before marking and drilling its mounting holes.
1968 Ford F100
I mounted this trick master... 
   
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1968 Ford F100
I mounted this trick master cylinder from CPP that I'll be using to double-check that nothing will interfere between the two masters before getting too far, and there seemed to be no issues. If you are using power brakes, be sure to include your power booster in the mock-up. I'll explain more about CPP's master cylinder when I plumb the truck.
1968 Ford F100
I cut this out of 1/8-inch... 
   
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1968 Ford F100
I cut this out of 1/8-inch cold-rolled steel and sprayed Dykem layout fluid on the backside to trace the holes for the clutch master cylinder. If you don't have Dykem, spray paint will work too-just clean it off before welding.
1968 Ford F100
Making the firewall thicker... 
   
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1968 Ford F100
Making the firewall thicker was only part of the battle. I also made this vertical gusset similar to the ones on the brake master cylinder's extra support and used a holesaw to put the 1-inch hole in the top for wiring to pass through. To avoid putting too much heat from welding into the firewall, I TIG welded the gusset to the doubler plate while it was off the truck with my trusty Miller Dynasty 200 TIG welder.
1968 Ford F100
The bolts that mount the clutch... 
   
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1968 Ford F100
The bolts that mount the clutch master to the firewall are perfect to hold the doubler tight to the firewall while welding the two together. I welded the top of the gusset to the underside of the cowl that hangs over the firewall, and to the left I welded the doubler plate to the brake master's extra support bracket. It's amazing how much this helped stiffen the area!
1968 Ford F100
A bracket needed to be built... 
   
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1968 Ford F100
A bracket needed to be built off the clutch pedal to connect the pushrod from the clutch master to it. I built this from the same 1/8-inch cold-rolled steel I used earlier. When mocking up the bracket, make sure the pushrod is level and not hanging down so it'll push straight into the clutch master cylinder.
1968 Ford F100
Because the pushrod is lower... 
   
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1968 Ford F100
Because the pushrod is lower on the clutch pedal than where the pedal would travel 1 inch once it hit its stop, I had to modify the pedal's stop to prevent the pushrod from traveling too much. With the straightedge ruler, I measured the center of the cross-bolt in the clevis on the end of the pushrod in its relaxed position, then pushed on the pedal until the center of the bolt traveled 1 inch. This is where I need to make the pedal stop.
1968 Ford F100
Next, we need to connect the... 
   
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1968 Ford F100
Next, we need to connect the clutch master cylinder to the clutch pedal, which gets tricky due to the cramped space under the dash. The ideal spot for the clutch master's pushrod is the vertical position on the clutch pedal where the pedal travels 1 inch once it reaches full travel, otherwise known as the floor. This can be measured with a level straightedge ruler from the firewall to the face of the pedal. Obviously, the pedal travels less the closer you get to its pivot point, so before starting any of this, make sure you mount the clutch master within this area and no more than 3 inches from the pedal's pivot point. In a perfect world, it would be nice to have the pushrod come through the firewall and meet right up with the pedal, but there wound up being about 3 inches of side-to-side distance between the two.

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1968 Ford F100  1968 Ford F100
1968 Ford F100  1968 Ford F100
 
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