June 3, 2007 - Brake Pedal, Reservoir & Lines
Finally, on to something new!  I started working on the brake pedals and lines.  First I gathered up all the components. 
Then I bolted on the pedals and brake cylinders.
Sorry for the blurry picture but I wanted to show you the washers that the drawings call for. 
Next step was to mount the brake reservoir on the firewall.  First I match-drilled the firewall, using the reservoir holes as a template.  I used the Unibit, Dremel tool and needle file on the big bottom hole.
My favorite Dremel tool bit.  Great for opening up holes. 
And the brake reservoir is mounted.  It's the first thing to be hung on the firewall. 
I screwed the blue AN fittings into the brake cylinders.  Since it was the pipe fitting end, I used the Loctite 565.  It's the white bead where the AN fitting goes into the gold brake cylinder.
The brake lines use nylon tubing.  Van's supplies the stuff to make the end fitting.  First you have to slide this little tube into the nylon tube, then pull a sleeve over the outside of the nylon tube.  The drawings suggested heating the nylon tube to make it easier.  I used my heat gun to heat it and did it without too much trouble. 
I screwed the gold fitting into the brake cyclinder using Loctite again.  Then I screwed the nylon hose to them.

I screwed the black hose to the bottom AN fittings.  The other end goes to AN fittings on the firewall.  Unfortunately, I had used those fittings to make my fuel vent inlets, so I'll have to order two more. 

Now that I'm starting to do some firewall stuff, I'm referring to my Firewall Forward book.  The Bingelis book series are a great resource for a new builder like me.
It's time to start the electrical system.  I had previously done some work on the battery box.  Now I need to finish it and mount it to the firewall along with the battery and starter contactors.

I dimpled the battery box and mounting brackets.  The flush head of the rivet goes on the inside of the box.  Because of that, I couldn't dimple three holes on each side because my squeezer yoke was too short.  The only solution I can think of is to borrow a longeron yoke from someone. 

I had bought these contactors from B&C Specialty.  Unfortunately, the plans are for the contactors sold by Vans.  So I'm going to have to deviate from the plans a little.
 
Previous
Home
Next