Repair Mount for Brake Booster? w/pics

I tore apart the brake booster mount for my Javelin to blast and paint. Unfortunately it's in worse shape than I thought. You can see from the pictures that the metal tube insert for the pivot is eaten clean through. There are also nylon inserts that go in there and they're worn out too. (Forgot to get a pic of those).

It wasn't, pressed fit IIRC. There is no stress on that tube, it's really just a spacer/bushing holder, it's not going to cause any problems used as is. It's hidden, I'd leave it alone, but if it bothers you you might consider grinding it down and slipping a piece of thin wall tubing over it instead of trying to remove and replace the tube. That will probably be a cut off and drill out operation, then tack weld a new one in place.

Thanks, I'd appreciate it. To repair I'll have to cut the bad half off and weld on a new piece of tubing. It's pretty cooked. I could easily crush what's left with a pair of pliers and minimum effort.  

Thought about weld/patch as I've had success with other unusual repairs. Maybe the pic doesn't show well, but for this I'd have to recreate half the tube. Then when done the inside would be crud and need a lot of work. Sliding in a half inch bar of brass or copper might do help, but don't have any handy. New section of pipe would be easier. If there's no alternative it will be a weld up job.

If you can't get a replacement, media blasting, welding the holes closed, building up the tube while using a brass shaft as a form inside looks a lot simpler than removing what's remaining of the tube and replacing it. Like others said, a die grinder or correct size mill will clean up the interior.
Brass round stock is available on ebay, and not that expensive. Flanged brass bushings are available from Aircraft Spruce and dirt cheap, less than $5 sometimes. They would work as an inner form.


Edited by White70JavelinSST - Jul/11/2016 at 8:35am