It's a 15/16" and i'm running 35x13.5 Toyo M/T which are really heavy. It stops really well that's what I meant by wiggle room, how much will a 16th hurt my performance vs piston size, amount of calipers/pistons as well as the other variables like brake booster size and pedal leverage?
Based on the numbers I've seen, more than you would think. 1/16" is tiny if you're measuring distance, but adding 1/16" or 1/8" in diameter ... you're talking about significant double digit increases in the percentage of area increase.
This is a really good read and he shows the math ...
4x4Wire - BRAKE UPGRADESWhat I expected based on his math is exactly what I ended up with. His calculations seem to be pretty dang accurate. Its pretty easy to figure out what you have now, and what you'd end up with if its not on his chart.
In my experience there's very little room between crap and awesome brakes and its really blurry in the middle.
Yes, there's wiggle in that a change 1/16" one way or the other won't result in totally inoperable brakes, but there's very little wiggle between 'ok' brakes and optimally operating brakes. Which makes sense. You need to move as much fluid as you need to move. Its just physics. Its not subject to interpretation.
Like my booster is half the size of the original Hilux booster and I was seriously worried about this but I cannot fit a larger booster (physically impossible) but fortunately for me it works perfectly and there's really no noticeable difference in braking feel from the donor rig. What's your take? Luck?
I haven't messed with boosters and only a little on non-Mitsu stuff. My experience is that getting the BMC volume and the calliper volume matched up makes a MUCH bigger difference than fiddling with the booster. The booster only does one thing and its function doesn't depend on the BMC or callipers. Its just a multiplier.
Going with the bigger Hilux booster would probably make a difference. It would probably make your brakes more sensitive - it would take less pressure on the pedal. Maybe a lot less - it is possible to go too far. My mom's '70 SS Nova has brakes that are so sensitive I think they're actually dangerous.
Knowing what I know now, I'd get my BMC and calipers matched up first. Then I'd see if the amount of pressure required on the pedal was where I wanted it. You DO NOT want a super sensitive brake on the trail. That is major suck.
If you needed a little more multiplication, in your case, I'd look at the pedal since changing out the booster isn't practical.
But, I'd make sure the BMC and callipers match first. It could turn out that fixing those makes such a huge difference that everything else is fine as it is. Like mine now, I see absolutely no reason to mess with the booster or pedal where before the swap a couple months ago, I was thinking of looking for a larger booster.
Edward
