Gav's 101.

Bit of an update, the disc brakes are all on and fit well. Very happy with how they fitted up and how ‘original’ they look having the deefer callipers on them - unless you knew Land Rovers, you’d think these came out of the factory like this (apart from them being all shiny when nothing else on the car is). 😉

Can’t bleed them up and test quite yet, I’m still trying to find a new brake/clutch reservoir for it as the old one is stuffed. Yes I know I can buy replacement 101 units, but at 70 quid each I’m looking for other options - it has a square dual reservoir unit on it at the moment from something (small truck or forward control people mover I think) so once I find something, I’ll be ready for testing I think.

PS is going well, but there’s a lot to that, so that’s the thing that will slow down testing of the brakes. All parts are in position, and turning the steering wheel moves the wheels through the new steering box now sort of, but all the fidley bits will take quite some time yet and I’ve still a few decisions to make before finalising everything.

Found and ordered new reservoirs and some flash fittings to suit. Aluminium reservoirs which ended up cheaper that plastic ones. Will finish off some brake lines I have to move tomorrow so I’m ready to bleed the system when the new parts arrive. 👍

Quote:

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Originally Posted by Homestar

Hi mate, great to see you here! Yeah I started doing that but had a very strong G&T instead so will have to try again some other time 😇. I’m unsure of the rear wheel cylinder diameters, but calipers have 4x46mm pistons x 2. How much travel of the pistons do you allow for? It’s bugger all in reality as the pads basically stay in contact with the disc at all times so 0.5mm sounds about right, so I’d actually assume very little required for the discs, so the 7/8” bore on the MC should work better for a disc brake setup than drums.

Hows the Volvo coming along? It’s been a few years since an update! 👍

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Volvo is not progressing and i'm not a great contributor unless I have something to say. On the plus side, I do have a nice new garage slab. [biggrin] Just need walls and a roof, then I can get on with the re-build in comfort.

0.5mm is what I read as the travel to be allowed for in the normal operation of the disks.
In addition, there is a ruling that says:-
Master cylinder reservoirs must have sufficient capacity, adequate for the total displacement volume of all wheel (slave) cylinders and calipers. Total displacement volume includes the volume of brake fluid necessary to accommodate the variation in volume from new to fully worn brake pads or shoes.

I struggle with this as I don't believe any vehicle meets this requirement - I was planning on not changing my reservoirs to meet, but I guess the VASS engineer will be the key here.

That’s interesting. So, for the fronts, there are a total of 8 pistons at 45mm each. Max throw from new to old on the pads is 12mm before I’m metal to metal, so if my calculations are correct, then that’s 18ml per piston, so 144ml. I’m running twin 125ml reservoirs but one does the fronts and one does the back and the clutch, so based on that not large enough... Hmmm...

And for the wheel cylinders, they are a 1" bore and there's 4 of them on the front drums. Assume say 1/2" travel from new to worn on the shoes and that's only just over 6ml per cylinder so only 25ml total for the front. Big difference and something I hadn't considered. Assuming making it so that both reservoirs are connected would be a no no due to only 1 failure point if I did that - maybe I need to use twin reservoirs on the front and a single for the rear. Have plenty of room to do this - will discuss with my Engineer.

what res did they originally use?

Dual plastic ones, similar to what I’m fitting - smaller than what I’ve ordered I believe but not 100% sure of their capacity. Mine had already had these replaced so was looking for alternatives anyway.

2 of these sort of thing - Single Brake Reservoir | 101 Parts - But the originals are plastic. These are very nice but bloody expensive. The anodised aluminium ones I bought were $34 each delivered.

Well the reservoirs turned up and are awesome, but a bit smaller than expected and given it looks like I need more capacity, I’ve ordered another and a tee piece so fronts will have dual reservoirs and rears/clutch the other. Will look very neat where they are going - I’ll make a bracket and mount what I have this weekend hopefully.

Ok, so that went well. Made a bracket to mount the 3 reservoirs and mounted the 2 I have. It will be easy to cut the tee in on the third when it turns up. Pick below. Bought genuine Aeroflow fittings and hose - that stuff is eye wateringly expensive but the only others I could find that would work were $2 eBay items and given the vibration, etc these get exposed to, I didn’t want to risk using cheap **** so bent over and paid the money. Can’t imagine how much it would cost in fittings and hose to do a race car or something similar...

https://live.staticflickr.com/65535/...679022e4_h.jpgIMG_0692 by Gavin Gregory, on Flickr

Ok, well got a HEAP done this weekend overall. No more pics sorry as a lot of it was the power steering conversion, which I'm not going into too much detail on here as far as pics and 'how too's go'. It's really something you feel comfortable undertaking or not, if you need a step b step guide on how to do these sort of things, it usually means you shouldn't be attempting it IMO. Got all of that sorted to a point it only needs a few parts cleaned and final assembly can take place. Still have the pump to mount to the engine, but that's a whole different job. It came out great, is very strong, and worked out better than I'd hoped for, but given doing things like this to vehicles throws up so many little jobs you never consider at first, I've spent hours running new brake lines, clutch lines, making customer brackets, etc. All in all it's some of my best work as I've made sure every last thing I touch is re done to a standard at least as good as the OEM did it - usually better. This has meant fitting and removing some parts 6 to 8 times to tweak things just right so they go back how I want them. I don't want to finish this job and still have those little 1% ers still hanging around - they are being done right first time.

All these jobs are part of making it rock solid for next years big trip so no point taking short cuts, that just defeats the point.

So hopefully I can get all the parts assembled for good after work this week as I actually need to be able to move it soon as the garage is getting some new equipment and I won't get that in with the 101 in the way.

That's a whole other story and something I'm very excited about (Think VERY heavy iron which is requiring me to upgrade the house electrics to 3 phase) [biggrin]