Got around to making a hydroboost setup last week. I originally bought a corvette master cylinder to try, but it was not large enough for what I needed. I ended up using a brand new 92 Astro van hydroboost and mated it to the 93 Dodge master cylinder. I made a bracket out of 3/8" steel to mount the setup to the firewall, and then added spacers on the drivers side of the bracket to give me some inward angle on the master cylinder. Right now the spacers are washers, but I will switch them over to some round aluminum spacers once I finally bolt in on the truck permanently. The spacers are necessary so the hood will close, as the hood tapers in towards the middle of the truck.
I also had to make the push rod inside of the hydroboost system as the new hydroboost did not come with the master cylinder push rod. The master cylinder mounting holes from the 93 also was slightly wider than the Astro hydroboost. I drilled out the mounting holes a little bit in the master cylinder and it fit just fine.
Some may ask "Why not just use the Astro master cylinder?" The answer is because the Astro master cylinder does not have a large enough bore and stroke size to properly match with the factory brakes on the 93 chassis. Plus I also would rather have a steel reservoir master cylinder, the plastic just looks kind of ugly lol.
After I mocked it up on the truck, I was able to see how long of a pedal travel would be needed. I wanted some pedal push rod adjustment just incase, so I made a threaded rod with a lock nut that has about 1" of adjustment.
For Pressure lines to and from the PS pump, hydroboost and steering box I am going to go with 6AN braided line. Russel makes adapters to use the 6AN fittings with the metric hole sizes found on the hydroboost, ps pump, and steering box.
I believe the hydroboost setup is well worth the $200 I will have into it once all is said and done. Stopping is important!