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NYsquarebird58's Brake System Overhaul and Disc Brake Conversion

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  • NYsquarebird58
    replied
    A few more pics of the booster/MC setup.



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  • NYsquarebird58
    replied
    Originally posted by DKheld View Post
    Glad to hear you are back in the wrenching mode Marcelo. You're gong to really enjoy driving the car with disc brakes - wish mine was back on the road (blown rear main seal). Thanks for the pics and letting us follow along - as Dave mentions great pics (almost as good as mine ).

    Might want to throw a small heat shield on the bottom of your prop valve since it will be right over the manifold ??? Not worried too much about the heat on the valve but rather on that plastic failure switch screwed into it. That stock booster bracket may get it all up high enough not to worry about.

    I had to extend my brake light wires when I mounted my prop valve down on the frame but looks like yours can stay stock - cool.

    Can't wait to hear your comments after the first disc brake drive.....

    Eric
    Thanks, Eric!

    I was thinking the very same thing about the heat shield. Hopefully I'll get this whole thing buttoned up in the next few weekends so I can do some fall driving.

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  • DKheld
    replied
    Glad to hear you are back in the wrenching mode Marcelo. You're gong to really enjoy driving the car with disc brakes - wish mine was back on the road (blown rear main seal). Thanks for the pics and letting us follow along - as Dave mentions great pics (almost as good as mine ).

    Might want to throw a small heat shield on the bottom of your prop valve since it will be right over the manifold ??? Not worried too much about the heat on the valve but rather on that plastic failure switch screwed into it. That stock booster bracket may get it all up high enough not to worry about.

    I had to extend my brake light wires when I mounted my prop valve down on the frame but looks like yours can stay stock - cool.

    Can't wait to hear your comments after the first disc brake drive.....

    Eric

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  • simplyconnected
    replied
    Originally posted by NYsquarebird58 View Post
    ...The Booster was filled with brake fluid!..
    And, the rest of the fluid was sucked into your intake manifold... Great job, Marcelo.

    Something struck me about the six holes on the firewall side of your booster bracket. Why six holes? Because Ford used the same bracket on full size Ford M/C's, which have different hole centers.

    If your booster was full of fluid, that means the old master cylinder was leaking too. Both of them had to be defective.

    Your new cunifer brake line bends look very professional and neat. I like how accessible you mounted the Stop Switch. It should be easy to change in future. Nice job. Real nice. - Dave

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  • NYsquarebird58
    replied
    A little bit more progress today. I repositioned the proportioning valve underneath the master cylinder and removed the bracket off the back of the booster.


    The Booster was filled with brake fluid!




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  • simplyconnected
    replied
    You're a good man, Marcelo. You take the best pics too. I'm really happy to hear you're back in the saddle again.

    Last night I had to make a panic stop in my Escort. The light turned red and there was no reason I shouldn't stop. Luckilly it was at night with light traffic.

    I hit the brake pedal HARD and the front left weel started pulsating violently but it did stop in time (but barely). I was two miles from home in a five speed stick, so I'm not really worried. When I resumed driving, the brake smelled badly and it kinda 'caught' on something, each revolution.

    At noon Saturday, I hoisted the car, set stands, pulled the wheel, and inspected the pads. The inner pad was gone but the outer pad was like new. Then, I noticed the small rubber 'bellows' on the guide pins were torn. Sure enough, there was rust inside which prevented the calipers from equalizing. The rotor's inside surface had a raised rust imprint from sitting a long time in one place. That caused the pulsing and it tore up the inner pad.

    The whole time I was working on these brakes I was thinking of you and your brake job. Were your ears burning?

    To make a long story short, AutoZone had pads and a caliper for under $55.00, and I was back on the road in no time.

    About your job... You may want to tuck the prop valve under the M/C, horizontally instead of beside it vertically. If you have the room, there isn't much difference.

    I'm anxious to see the results when you grid the rivets off the old booster and mount the firewall bracket to your new two-stage booster. The old girl is REALLY going to like her new brakes. - Dave

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  • NYsquarebird58
    replied
    I'm Baaaaacckkk!!!!

    It’s been just about four months to the day since I hurt my finger, but I’m back and good as new!

    Today I picked up where I left off, and I gotta’ tell ya’, it felt good to wrench on the old bird again.

    I removed the old booster and master cylinder and plumbed the proportioning valve to the new master cylinder. Tomorrow I’ll see about mounting it all up to the firewall.









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  • simplyconnected
    replied
    Not yet. It was Mother's Day and here's what we did:
    CLICK HERE
    I'm only in a few pics (#13) as I was the photographer of the day (in the Thunderbird shirt).

    I anticipate the swap will go very quick (and smoothly). For the past few days I've been tied up and DYING to get back to Penelope's job. The Galaxie has a M/C that works but the new one will be an improvement. Since it was raining the other night, I used that time to bench bleed:

    I simply bend two old brake lines into the reservoirs. It is important the ends are submerged in the liquid. Notice one line has a plastic tube? When done, I connect the two temporary steel lines with that plastic tube until I'm ready to plumb the M/C. It just makes the job a little neater. When it's plumbed, I will throw the temp pieces away. - Dave

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  • NYsquarebird58
    replied
    Originally posted by simplyconnected View Post
    I bench bled my new M/C tonight, Marcelo. It took foreeeeeever. I honestly thought one of my fittings was sucking air. Nope! It takes a lot of patience because little tiny bubbles keep coming with 1/4" strokes. You'll see...

    Take care and enjoy your time off, as much as you can. Glad to hear your company came through for you and the operation is a success, so there's no worries. God Bless... - Dave
    Hey Dave, did you mount that new MC yet?

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  • simplyconnected
    replied
    I bench bled my new M/C tonight, Marcelo. It took foreeeeeever. I honestly thought one of my fittings was sucking air. Nope! It takes a lot of patience because little tiny bubbles keep coming with 1/4" strokes. You'll see...

    Take care and enjoy your time off, as much as you can. Glad to hear your company came through for you and the operation is a success, so there's no worries. God Bless... - Dave

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  • NYsquarebird58
    replied
    Originally posted by Dakota Boy View Post
    that x-ray pic with the loose bone chip gave me the willies.

    did you say some bad words when that happened?
    Yeah and I think I may have invented a few too!

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  • Dakota Boy
    replied
    that x-ray pic with the loose bone chip gave me the willies.

    did you say some bad words when that happened?

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  • NYsquarebird58
    replied
    Thanks Eric and tbirds8. I wont be wrenching for a while but I'll still keep progressing with the project. I'll be ordering wheels and wide whites very soon. When I'm well enough, I'll bring them over to the bodyshop to get painted and then I'll have the tires mounted. I'm sure there are others little projects I can handle until I can pick up a wrench again. Boredom is the biggest killer. I gotta keep busy.

    Here I am just out of surgery. It was a success; they were able to reattach the tendon and remove the loose bone fragment.

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  • Guest's Avatar
    Guest replied
    That would be a good way to get the parts off the table. Ha Ha Get well and I know your gona push it.

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  • DKheld
    replied
    Been out of town - catching up on some of the threads

    UGH - sorry to hear about the finger Marcelo. Guess you'll just have to use one foot and one hand while the finger heals.

    X2 on Astrowings comments - everybody re-think and be safe!

    ( I think Dave is trying to get you in trouble - )


    Eric

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