Rupunzell
Bernice Loui
Time to re-do the pedal box for the 74.
OEM Fiat cylinders were sent to Karps Brake for sleeving in Stainless steel (304). At this point in time, I flat refuse to use the current afermarket replacement cylinders are they are not equal to Fiat OEM. This is the innards of the clutch master with new seals installed. The moving parts are coated with Dupont Krytox O-ring lube.
Since this Fiat clutch master has the press in with spring clip and O-ring plastic inlet fitting.. that are not replaceable, the choice was made to thread the inlet port with a M24x1.5 tap and make a special fitting to allow using a 1/8" NPT threaded 37 degree -4 JIC fitting. The M24 to 1/8 NPT fitting was torqued to 50 ft/lb.
Here is what the clutch master looks like when assembled:
Side view:
The fittings are installed with Loctite PTFE sealer on the inlet fitting. The M24 copper crush washer was re-used. This can be done by heating the copper washer to cherry red hot and allowing it to cool slowly. This anneals the copper allowing a proper seal. If this is not done or a new copper washer used, the fitting will not seal.
For the Brake master, Aluminum fitting were made in place of the OEM plastic. This allows 37 degree -4 JIC fittings to be used in the inlet hoses.
The inside of these fittings are cone shaped to help air bubbles move out out of the fitting. Air bubbles can sit inside of the fitting if there are flat areas within the fitting.
Top view of the brake master cylinder. This is a Lancia Scorpion brake master with the single front outlet.
Side View:
Fiat OEM and part number in casting:
The Wilwood brake pressure valve and mounting bracket parts:
Bracket and Wilwood valve. The fittings are 37 degree JIC -3.
Wilwood valve on bracket:
Some time ago, this pedal box was bead blast cleaned, primer-ed with zinc phosphate and finished with silver paint. Another bearing bronze bushing for the pedals got made and this the beginnings of putting it together.
View of the bearing bronze bushing, slot and new brake switch with push rods that are in prime condition. These push rods and pins on the pedals wear badly if neglected and causes pedal feel problems and lots of slop in the pedal system. Pins, push rods and ball joint ends were lubed with Swepco 101 Moly grease. New washers and stainless steel cotter pins installed. Main pedal bushing was lubed with Redline CV moly grease.
View of the Wilwood brake valve and bracket on the clutch master side:
These are the long bolts that mount the master cylinders. The long bolt is M8 x 195, shorter one is M8 x180. These are old and tired. As most know, I don't like re-using hardware if at all possible. Since AN-5 bolts of this length cannot be easily had, new 5/16 x 24 tip, 8.00" long, SAE grade 8 bolts were purchased then modified as the threads are too long. The threads are just long enough for the nut/washer. (about 2 to 2.5 thread diameters).
Side view of the clutch master with WIlwood valve and bracket. One of the brake tubing has been made and installed, Note the caps on the fittings waiting for tubing. This is done to keep stuff that should not be in the brake system out. Everything is kept as clean as possible as the work moves forward:
Brake master side with the old M8 bolts used hold the cylinders in place as the brake lines are made.
Top view of the pedal box with brake lines installed and 1/4" Gate Adapta-flex EPDM hose with JIC 37 degree barbed fittings on the inlet side of the masters.
Part two, filling the cylinders, purging air and testing.
Bernice
OEM Fiat cylinders were sent to Karps Brake for sleeving in Stainless steel (304). At this point in time, I flat refuse to use the current afermarket replacement cylinders are they are not equal to Fiat OEM. This is the innards of the clutch master with new seals installed. The moving parts are coated with Dupont Krytox O-ring lube.
Since this Fiat clutch master has the press in with spring clip and O-ring plastic inlet fitting.. that are not replaceable, the choice was made to thread the inlet port with a M24x1.5 tap and make a special fitting to allow using a 1/8" NPT threaded 37 degree -4 JIC fitting. The M24 to 1/8 NPT fitting was torqued to 50 ft/lb.
Here is what the clutch master looks like when assembled:
Side view:
The fittings are installed with Loctite PTFE sealer on the inlet fitting. The M24 copper crush washer was re-used. This can be done by heating the copper washer to cherry red hot and allowing it to cool slowly. This anneals the copper allowing a proper seal. If this is not done or a new copper washer used, the fitting will not seal.
For the Brake master, Aluminum fitting were made in place of the OEM plastic. This allows 37 degree -4 JIC fittings to be used in the inlet hoses.
The inside of these fittings are cone shaped to help air bubbles move out out of the fitting. Air bubbles can sit inside of the fitting if there are flat areas within the fitting.
Top view of the brake master cylinder. This is a Lancia Scorpion brake master with the single front outlet.
Side View:
Fiat OEM and part number in casting:
The Wilwood brake pressure valve and mounting bracket parts:
Bracket and Wilwood valve. The fittings are 37 degree JIC -3.
Wilwood valve on bracket:
Some time ago, this pedal box was bead blast cleaned, primer-ed with zinc phosphate and finished with silver paint. Another bearing bronze bushing for the pedals got made and this the beginnings of putting it together.
View of the bearing bronze bushing, slot and new brake switch with push rods that are in prime condition. These push rods and pins on the pedals wear badly if neglected and causes pedal feel problems and lots of slop in the pedal system. Pins, push rods and ball joint ends were lubed with Swepco 101 Moly grease. New washers and stainless steel cotter pins installed. Main pedal bushing was lubed with Redline CV moly grease.
View of the Wilwood brake valve and bracket on the clutch master side:
These are the long bolts that mount the master cylinders. The long bolt is M8 x 195, shorter one is M8 x180. These are old and tired. As most know, I don't like re-using hardware if at all possible. Since AN-5 bolts of this length cannot be easily had, new 5/16 x 24 tip, 8.00" long, SAE grade 8 bolts were purchased then modified as the threads are too long. The threads are just long enough for the nut/washer. (about 2 to 2.5 thread diameters).
Side view of the clutch master with WIlwood valve and bracket. One of the brake tubing has been made and installed, Note the caps on the fittings waiting for tubing. This is done to keep stuff that should not be in the brake system out. Everything is kept as clean as possible as the work moves forward:
Brake master side with the old M8 bolts used hold the cylinders in place as the brake lines are made.
Top view of the pedal box with brake lines installed and 1/4" Gate Adapta-flex EPDM hose with JIC 37 degree barbed fittings on the inlet side of the masters.
Part two, filling the cylinders, purging air and testing.
Bernice