The Bosch "iBooster" also runs in "failsafe" mode when no CAN input is detected, so for basic operation, only 12V, switched 12V and GND connections are required. It's quite compact, the original master cylinder can be mounted using a simple steel adapter plate (edit: might even be able to use the Model 3 master cylinder, as it's 1" (26mm) bore, I believe the same as my '03 NB's), and the body/pedal box mounts can be made to work with a bit of fabrication. I work in product developer for a major OEM and the use of EBBs is increasing, as is their availability at the breakers yards.īosch makes a nice range of "iBoosters" which are available in several vehicles, but the one I think I will try to work with is from the Tesla Model 3. I plan to have its controller talk to the ECU (ME221 currently) to take vehicle speed and adjust the assist level accordingly. Yet to be completed, but I think it will be a good solution. £100 for the EPAS column, £15 for the donor NB column, a few beers for the cutting/welding. Instead, I have taken an EPAS column from a scrapped Vauxhall Corsa B, a popular source for these things in Europe, and will be using a spare NB column as donor to fabricate the mounts to suit the NB. Also import duty and shipping double the cost. Since these convert electricity to mechanical work directly instead of via a hydraulic or pneumatic middle-step, these solutions satisfy my neurotic engineering OCD a little better.įor the EPAS, I am unlucky enough to have a RHD (UK car) and therefore (as far as I have been made aware) cannot use the existing EPAS column made available by a couple of vendors in the US. They feel like bandaids in my opinion, although I'm sure they work perfectly well.Īs part of my long-term EV conversion plan, I have decided to go with EPAS and an Electric Brake Booster (EBB). The Bosch iBooster is an electromechanical brake booster (rather than vacuum assisted) primarily found on Electric Vehicles such as Tesla, but can also be found on other vehicles including ones with an Internal Combustion Engine.Specifically in the ZeroEV conversion but also in other EV-hotrod conversions, I have seen the power steering pump and brake booster vacuum source replaced with electric pumps in order to retain the original PS rack and brake booster.Īlthough I like the reversibility of this approach, the engineer in me is uncomfortable with these as solutions. The iBooster is able to run in a fail-safe standalone mode with no other connections or communication to additional components needed besides voltage supply and chassis ground as the iBooster has an internal Pedal Travel Sensor that is externally wired to the iBooster ECU. Therefore the iBooster is an ideal component for many applications such as electric vehicle conversions (rather than using a vacuum pump), classic cars / muscle cars / hot rods (typically with manual brakes), limited vacuum pressure (such as diesel or turbo engines), or clearance issues of engine swaps (like the BMW E30 with a S54 engine).īosch iBooster Gen-1 Connector Kit Contents: The information from the Pedal Travel Sensor is used by the iBooster ECU to drive the electric motor which provides additional force towards the Master Cylinder. 5x – Pins for 0.50 – 0.75mm² wire and Seals for 1.4 – 2.1mm insulation diameter ( 1 spare, see recommended wire).ġ0x – Small Pins for 0.35 – 0.50mm² wire and Seals for 1.2 – 1.6mm insulation diameter (4x for CAN-Bus*, 1 spare, see recommended wire).2x – Medium Pins for 1.50 – 2.50mm² wire and Seals for 2.0 – 2.7mm insulation diameter (1 spare, see recommended wire) Bosch iBooster Gen-2 Connector Kit Contents: 10x Small Pins for 0.35 0.50mm² wire and Seals for 1.2 1.6mm insulation diameter (4x for CAN-Bus, 1 spare, see recommended wire) To our knowledge CAN-Bus integration and custom tuning of the iBooster has not been achieved yet but we opted to include the additional pins and seals if.3x – Large Pins for 2.50 – 4.00mm² wire and Seals for 3.4 – 3.7mm insulation diameter (1 spare, see recommended wire).* To our knowledge CAN-Bus integration and custom tuning of the iBooster has not been achieved yet but we opted to include the additional pins and seals if you wish to experiment or if this becomes viable in the future. – There are two versions of the Bosch iBooster Gen-1 and Gen-2. With the iBooster, Bosch has developed a vacuum-independent, electromechanical brake booster that meets the demands of a modern braking system. Be sure to order the correct kit based on the style of Pedal Travel Sensor Connector, and use the correct wiring pinout. highly dynamic A fast pressure build-up enables short stopping distances for automatic emergency braking and covers future NCAP requirements. – All items within this connector kit are genuine items sourced from authorized distributors.
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