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Thread: Bosch iBooster Retrofit

  1. #1
    Customized Member 81dmc's Avatar
    Join Date:  Feb 2013

    Location:  Magnolia, TX

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    Bosch iBooster Retrofit

    Seeing as the ibooster is capable of standalone operation, I'm deciding to retrofit my car for the hell of it.

    I was able to buy one from a Tesla for about $80 on ebay, so I could not resist...


    So I went ahead and drilled new holes into the brake booster mounting bracket and did a test fit.


    Very tight, but it fits perfectly.

    More to come, but first I need to find the connectors...
    Rodolfo

    SPEC I Stainless Exhaust, Delorean.eu Roof Box, Kenwood Double Din, Black Leather Interior, Improved Wiring, Custom Dakota Digital Instrument Cluster, QA1 Suspension, Rostra Cruise Control

  2. #2
    Senior Member Patrick C's Avatar
    Join Date:  May 2011

    Location:  Northern Michigan

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    Club(s):   (DCO) (DCUK)

    Nice work! Keep us posted!
    Patrick C.
    VIN 1880
    Modifications done to my car can be seen in this video: http://www.youtube.com/watch?v=_yUpusPAvJc

  3. #3
    Senior Member Josh's Avatar
    Join Date:  Mar 2013

    Location:  SK, Canada

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    This is so cool, love seeing stuff retrofitted like this to modernize the car.

  4. #4
    Senior Member vwdmc16's Avatar
    Join Date:  May 2011

    Location:  sacramento

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    Club(s):   (NCDMC) (DCUK)

    That's a neat set up.

    Curious how different that will feel.

  5. #5
    Customized Member 81dmc's Avatar
    Join Date:  Feb 2013

    Location:  Magnolia, TX

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    My VIN:    831

    After doing a bit of thinking, I came to the conclusion that some other EVs equipped with adaptive cruise must use an ibooster. Sure enough, after looking on TechAuthority, I found that the 2017 Chrysler Pacifica PHEV uses an ibooster. So now I have the pin outs and part numbers for the connectors.

    For the ecu connector...


    For the pedal sensor connector...


    The pedal sensor connector and its pins are easily found on Mouser, as it is manufactured by TE Connectivity. The large ecu connector, however, is a Bosch part which is very difficult to find. However, after looking deeper, I was able to purchase the pins from Nexus Electronics and the housing from Aliexpress in China.

    More to come once I get everything together.
    Rodolfo

    SPEC I Stainless Exhaust, Delorean.eu Roof Box, Kenwood Double Din, Black Leather Interior, Improved Wiring, Custom Dakota Digital Instrument Cluster, QA1 Suspension, Rostra Cruise Control

  6. #6
    Customized Member 81dmc's Avatar
    Join Date:  Feb 2013

    Location:  Magnolia, TX

    Posts:    548

    My VIN:    831

    A Little Progress...

    Just cut the bubble flares off my lines and reflared them to inverted double flares. I'm using an m10 1.00 on the line. And since the Tesla master uses m12 1.00, I ordered two adapters from ebay.
    Rodolfo

    SPEC I Stainless Exhaust, Delorean.eu Roof Box, Kenwood Double Din, Black Leather Interior, Improved Wiring, Custom Dakota Digital Instrument Cluster, QA1 Suspension, Rostra Cruise Control

  7. #7
    Customized Member 81dmc's Avatar
    Join Date:  Feb 2013

    Location:  Magnolia, TX

    Posts:    548

    My VIN:    831

    Test Video

    The ibooster has been installed. The wiring is just tapped into 12v for testing, and I will eventually run everything correctly.


    The hydraulics are still disconnected until this weekend. Will make another video once everything is fully functional.
    Rodolfo

    SPEC I Stainless Exhaust, Delorean.eu Roof Box, Kenwood Double Din, Black Leather Interior, Improved Wiring, Custom Dakota Digital Instrument Cluster, QA1 Suspension, Rostra Cruise Control

  8. #8
    Customized Member 81dmc's Avatar
    Join Date:  Feb 2013

    Location:  Magnolia, TX

    Posts:    548

    My VIN:    831

    Fully Operational

    Well today I received the m12 to m10 adapters. I quickly installed and bled the system using Valvoline DOT 3 and 4.

    Unfortunately, the 2017 Chevy Volt reservoir is just a tad too tall. So either I will modify the access cover, or I will remote mount a reservoir using an adapter from a Honda CR-V.

    Here's a couple pics of it installed. The wiring is only temporary, as the connector housing has not shipped yet from China.




    Now when it comes to the feel, all I can say is WOW! With everything together, the car now brakes as effortlessly as a modern sports car. No hard pedal. No jamming brakes in emergency situations. And this is all with the original calipers...

    Here's a poorly made video of an emergency braking test.

    Rodolfo

    SPEC I Stainless Exhaust, Delorean.eu Roof Box, Kenwood Double Din, Black Leather Interior, Improved Wiring, Custom Dakota Digital Instrument Cluster, QA1 Suspension, Rostra Cruise Control

  9. #9
    Senior Member powerline84's Avatar
    Join Date:  Mar 2015

    Location:  NY

    Posts:    459

    My VIN:    2706

    Dude this is badass....someday when my completely brand new brake system needs returbed I may go this route.

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