Chassis

Servo upgrade complete

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Paint on the back of the adapter to avoid any rust

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A tube of  heat shielding goes over the brakes hoses, this adds extra heat protection as they run past the servo underneath it.

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The most useful tool ever in a situation where you can’t see – a camera on the end of a long bendable probe!

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Snake cam, allowed me to easily locate bolts and screws while using the laptop screen to see what was going on.

With the aid of this tool I bolted up the rose joint to the brake pedal.

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Old heat shield adapted and fitted under the master cylinder, the extra tube covers from the heat shield back.

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The heat shield keep everything nice a cool as it’s directly above the exhaust manifold. The servo gets close to the side, but there’s more than enough room!

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Lots of clearance for the bonnet to close.

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Here is is all back together again! Took it for a quick test drive, it was cold dark and the first time I’ve needed to use the fog light on the car!

Initial impressions – pedal travel is longer, but way more progressive. The feel is much more like my tintop – not as much bite but much easier to use.

Took it out again today and tried a few emergency stops, it stop nice and straight and you can pump the pedal relativity easily to stop the wheels from locking. All in all a very good upgrade!

Chassis

Brake hose installation progress

Made good progress today installing the new flexi brake hoses from the master cylinder. The pressure reducer for the back is relocated just above the steering column and all 3 pipes have been chopped and re-flared.

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Flexi pipes for the front brakes fitted to the chassis, the old brake pipes are still as there were.

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Master cylinder adapter plate painted a nice shade of hammered blue.

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Copper shortened and re-flared to fit flexi pipe locations and the pressure reducer for the rear brakes relocated to just above the steering column.

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Pressure reducer as seen from the top.

Chassis

Pretty bakes hoses

Got hoses this week, they’re really nice – custom made by siliconhoses.com to order. Ordered Sunday night arrived Tuesday morning.

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Chassis

Woo parts!

Received parts – rose joint with right hand thread which fits on the servo from eBay and some 3/8″ nuts, washers and bolts to attach it to the pedal. Bolts came from namrick and rose joints from McGill Motorsports.

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Chassis

Servo installation continues

Finished off machining the adapter plate today, brought some proper countersinking bits with me! Had to machine down the bolts ever so slightly to fit in to the counter sunk holes.

Bought a rose joint to go on the servo, minor issue bought the wrong thread direction – oops! New one on order LOL. Also 10mm bolts don’t go through 3/8″ holes by about 0.4mm so ordered some 3/8″ nuts and bolts to use.

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Chassis

Brake servo upgrade

Started on swapping out the metro brake servo for a dual diaphragm servo bought as part of a group buy on madabout-kitcars.com.

So far I’ve fitted the new servo by expanding the mount holes of the old servo, extended the push pin with a bolt and started making the servo to master cylinder adapter.

Need to wait for a rose joint to connect the servo to the brake pedal – didn’t like the idea of putting an oval in the the existing connector. Also my counter sinker isn’t making much of dent in the servo master cylinder adapter plate so need a better one!

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