Monte# 209, Pedal box ready to install.

[Rupunzell]

Took more effort to do than the exxe pedal box.

74' Pedal Box Project

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...

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The Lancia pedal box has a different design in various ways even when both master cylinders are essentially the same.
AN-4, JIC 37 degree fittings are used again for the brake fluid inlets. These have been good in many ways.
Making the double stamping brake pedal was not simple, but should help with pedal flex due to the offset angle not found in the exxe brake pedal (it's a better design in some ways). Added a 19mm hex head to the clutch spring plate to ease installation.

Oem Fiat master cylinders were sent out for stainless steel sleeving, rebuilt with new seals and related parts. The current aftermarket replacement master cylinders are hideous inside.. they do work, but.. no thanks. Tubes and tube nuts were good, they got re-used.

LH side.

RH side.

Front.

Top.

Bernice

 

[lanciahf]

Bernice,
As always nice work. Thanks for sharing.
Thanks
Ralph

 

[fiatfactory]

what's the fitting that connects the master cylinder to the JIC fitting?( I've been thinking about doing this as well)

SteveC

 

[Rupunzell]

Those master cylinder inlet fittings are are "one-off" They are M24x1.5 external threaded with 1/8"x27 NTP threaded internal with a 15mm hex to install them into the master cylinder inlet ports. The 15mm hex was chosen to allow clearance to the internally threaded M24 inlet ports with a socket and allow enough material for the 1/8"x27 NPT threads.

~In process of what the master cylinder inlet ports look like with these fittings.
The brake master cylinder is exxe, which has one extra outlet for the front brakes. It is blocked off with a ball bearing
and brass plug with Loctite# 576 thread sealer (all that white stuff on the fittings).

M24 fitting being made on the lathe. Has a shoulder to seal against the bottom of the master cylinder's
inlet bottom. Fitting cannot leak.. ever.

Cutting the 15mm hex using a 5c collet indexer on the Bridgeport milling machine.

Back side of the brake pedal has a zerk fitting to allow lube of both brake and clutch pedal bearing.

Threading the master inlet port using a M24x1.5 bottoming tap. This was from the exxe pedal box project.
same operation. The master cylinder is taken apart, cleaned, inlet ports bored to tap size for M24x1.5 then threaded.
Master cylinder housings are then sent out for stainless steel sleeving.

Bernice

what's the fitting that connects the master cylinder to the JIC fitting?( I've been thinking about doing this as well)

SteveC

 

[fiatfactory]

Those master cylinder inlet fittings are are "one-off" They are M24x1.5 external threaded with 1/8"x27 NTP threaded internal with a 15mm hex to install them into the master cylinder inlet ports. The 15mm hex was chosen to allow clearance to the internally threaded M24 inlet ports with a socket and allow enough material for the 1/8"x27 NPT threads.

Thanks, I was mostly wanting to know the thread size. you'd used, I'd probably start with somehting like this rather than starting from scratch.

SteveC

 

[ls scorpian]

beautiful job, I just rebuilt mine also. I'm wondering about bleeding procedure now that it's installed, I'm hoping it can be bled at
firewall (the front one!), have you bled it yet? The rest of my brake system will be upgraded, so it won't see fluid for quite awhile.

 

[Rupunzell]

About 3 years later... This pedal box got installed back into# 209..

Plumbing connected:

First try, discovered the M8 bolt for the master cylinders had to be reversed as the extra length from the bolt/nut end
runs into a relay mounted on the fuse box.

Done, button up the hoses, then add brake fluid. First is the clutch system as that is essentially complete.
Brakes after the calipers checked/rebuilt/replaced as needed and hoses (replaced) and all have been verified good.
Notable is the bottom curvature of the accelerator pedal (the assembly was completely re-done with ball bearings) specifically designed for toe/heel. The oversized brake pedal pad is from Saab 9000.

Bernice

 

[mikeroten]

talk to me about those fittings into the tops of the masters. I have had the plastic ones fail on my car.

edit: derp, didn't read far enough back. beautiful!