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I just put on a set of the SS brake lines form Sector 111 and porterfiels R-4S. The brake feels much better (stiffer and shorter stop time).

I have one question the brake still travel a lot. The excessive travel make it hard to heal toe. Is this normal and if so is there a fix.
 

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I just put on a set of the SS brake lines form Sector 111 and porterfiels R-4S. The brake feels much better (stiffer and shorter stop time).

I have one question the brake still travel a lot. The excessive travel make it hard to heal toe. Is this normal and if so is there a fix.
It is definitely normal for 05 cars; I don't know if later cars are that much better. There are various ways to make the set-up friendly to heel-toe, but as far as the "free travel" in the brake pedal, there's no fix I know of. (FWIW, my set-up works for heel-toe: The gas pedal is lowered as much as possible via its adjustment range, and I have a Sector111 heel-toe pad on the brake pedal.)
 

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This was a common issue on '05s. There is an adjustment to bring the brake pedal up to facilitate heel and toe. Do a search. You should find plenty written about this back in late '04 to '05.
 

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Nitro,

The problem with the excessive brake pedal travel is caused by the tolerancing on the output rod of the brake booster. Basically, it is too short and there is a gap between the output rod of the booster and the piston of the master cylinder. How do I know this? I made an adapter plate to mount the master cylinder and removed the booster altogether. Now the pedal is as hard as a rock and there is nearly zero travel before the brakes actuate. Search for threads I have replied to as there was really good thread about a month ago where I told the whole long story.

I still havent worked out an acceptable solution but I need to soon.

Tony
 

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My 968 had the same problem with the tolerance between the booster an MC. I Had thought about fabbing a spacer that could be adjusted with shims or a two-piece threaded spacer, but never got around to it. I'd be very interested in a solution for the Elise. Dead travel is one of my pet peeves, especially when the Tacoma I had didn't exhibit ANY.
 
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