Thread: Every 3 years

Continuing on (as you do LOL) I'm not having any joy with the brake system on my 109.
This is what has transpired over the past day, remove brake pendant assembly
http://i659.photobucket.com/albums/u...w/IMG_0993.jpg
it has become apparent to me, that for some reason the piston is sticking in the M/cyl. After taking it apart and stripping it down in my humble opinion the rubber seal (on piston) looks to be of dubious quality, and has grown a little in size, thereby causing the piston to stick in the cylinder
http://i659.photobucket.com/albums/u...w/IMG_0992.jpg

Anyway back to issue at hand, I noticed that the push rod didn't seem to have enough length, so a quick look around and I found these 2 items
http://i659.photobucket.com/albums/u...w/IMG_0991.jpg
but being rolled threads I wasn't keen to use either of them, I did eventually find a genuine one on an old CB cylinder and fitted it.
A quick try with it set up in the pendant holder, soon showed a fault, the retaining washer that holds the piston etc, the opening wasn't big enough for the 5/16" push rod (remember the other rolled thread) this was noticed while operating the assembly by hand, it appeared to jam at the downward stroke, well it ?? might have had just enough clearance, anyway I opened it up using a 11.5mm drill.
http://i659.photobucket.com/albums/u...w/IMG_0994.jpg
I've put it together without the seal and reassembled the cylinder in the pendant setup and all appears to work without getting stuck anywhere, the next issue is where to source a kit for this cyl.
My usual brake service closed yesterday for xmas, I did try another couple without any joy, so it looks like this job has hit a wall until late next week or the 2/1/13, anyway cheers Dennis

Well the brake service company has re-opened and we drove to East Maitland to try our luck with a new seal, after much tooing n froing with parts books we came up with (I hope) is the correct seal, I fitted it soon after arriving home.
I run up the compressor so I could clean the bore of the Master cylinder
http://i659.photobucket.com/albums/u...w/IMG_1006.jpg
a light lube of brake fluid and the piston and seal slide in the bore, like the proverbial finger, but best of all, the piston and seal move freely in the bore and the return spring has enough grunt to bring the piston back to rest
Five minutes later (with help from swmbo) I had it fitted to the pendant and touched it up with Gloss Black paint, just need the paint to dry and I will refit it
http://i659.photobucket.com/albums/u...w/IMG_1007.jpg, fingers crossed that I don't have any issues bleeding it, LOL cheers Dennis

looking good Dennis, love your work

After a period of nothing happening due to work commitments, I have still to properly bleed the system. I have located the source ?? where the air is by using my Girling brake hose clamps, the air ?? lock is in the rear.
I have tried using my MityVac vac/bleed system but it seems to be pulling air around the bleed nipples, so I have been fiddling with trying something else, a Pressure bleeder. I used to own a Girling pressure bleeder but it was stolen from me about 27 years ago when I split with my 1st wife, anyway it's gone who knows where.
I found a suitable piece of Aluminium round bar to use as a lid that I can tap into to apply air pressure. I determined that the thread size on the M/cyl reservoir appeared to be 8TPI
http://i659.photobucket.com/albums/u...w/IMG_1018.jpg
now I know that this particular thread wasn't screw cut, more like pressed/rolled, but I had a plan in my head how to get around that issue, anyway after much tooing n froing on my lathe, this is how it finished
http://i659.photobucket.com/albums/u...w/IMG_1020.jpg
and it doesn't cross thread, it is fairly smooth with engagement, I'm fairly happy with the result so far
http://i659.photobucket.com/albums/u...w/IMG_1023.jpg
it still needs to be reduced in size at the top, but at the moment it's comfortable for my arthritic hands?? anyway cheers Dennis

Originally Posted by Carzee

Hey up there, you have been busy. Just read the Sawmill saga. Unbelievable result! You should get a gong. You are the best.

So is this Workshop ready for action again or are you taking a break for Christmas shopping?

cheers!

Good grief! It's himself....

The pressure brake bleeder I ordered from the United States has cleared customs in Sydney, it will probably take until Thursday before I get it , meanwhile the Wksp Land Rover just sits around waiting LOL anyway there is always something else to be done in the meantime, cheers Dennis

The pressure bleeder arrived today, I was pleasantly surprised to see that it has a cap to suit Land Rover Yeh I thought, but a quick look at the thread type and it was clear to me that it wasn't going to suit the S2A, and I was correct , anyway on the upside it does suit L/R from S3>>110, quite a bit of kit with it, I won't be doing anything with it as yet, because I will now have to buy/steal from any of my other air tools the snap on fitting for the air hose, anyway the unit
http://i659.photobucket.com/albums/u...0/IMG_1082.jpg
cheers Dennis
big storm brewing outside,,.

Well after looking at the snap on fittings that came with the brake bleeder, nothing I had was interchangeable!!!, isn't always the same.
I had a scrounge about in my brass shelf and came up with 2 suitable pieces of brass hex that I could make into what I needed, this is what I needed to copy
http://i659.photobucket.com/albums/u...0/IMG_1083.jpg
after a short period of time it looked like this
http://i659.photobucket.com/albums/u...0/IMG_1085.jpg
a quick check to see if it would fit n seal
http://i659.photobucket.com/albums/u...0/IMG_1087.jpg
and it did, it was a neat fit, not loose or wobbling.
Next to make a right angle adaptor from brass hex and cut a thread into the alloy brake M/cyl top I make a few weeks ago
http://i659.photobucket.com/albums/u...0/IMG_1088.jpg
I needed to make a gasket to suit the inside of the alloy cap, some thin rubber sheeting was found and cut to suit, all items screwed into place, damn !!!! an AIR leak.
It was determined that it was coming from under the gasket, after looking at the job for a while, I put the alloy cap back in the lathe, set it off the mark against No1 jaw, put in a tool that I could cut a groove for the gasket to seat into, this was done without too much fuss, cut another slighly larger dia gasket, try n fit, remove trim a snippet, try n fit, this time as snug as, gasket sitting flat, well lets give it a try with some pressure.
I pumped the brake bleeder to 5psi, fitted the cap to an old M/cyl holding two fingers over the outlets, open the inline valve, success
no air leaks and holding 5psi, as can be seen in the image
http://i659.photobucket.com/albums/u...0/IMG_1089.jpg
anyway thats enough excitement for one day, I will have to buy some brake fluid in the morning and try it out on my 109 Wksp truck, cheers Dennis