Saved $2 ended up costing $1000's, - Master Cylinder Grommet Washers Options

[Kansas 914]

I bought my /6 last year pretty much complete. Everything was well done. 911 suspension all around. 911 brakes all around including drum emergency brake on the rears. It appeared to be a "no costs spared" restoration.

Here is the detail on just the brakes: "Brake system was upgraded in many ways. Porsche 911E front struts were installed in order to handle Porsche 911S "A" calipers. New vented front and rear 911 brake rotors. All metal brake lines and rubber hoses were replaced. The rear brake calipers are rebuilt and come from a Porsche 911S. Factory spacer shims added to the rear "M" calipers to accommodate the vented rotors. A machined spacer was added to the inside of the new rotors to align the rotor centerline to the caliper centerline. New factory rear stub axles were purchased in Germany to complete the five mounting bolt wheel conversion. The parking brake system is now the Porsche 911 type brake shoes within the brake rotor design."

Last week I decided it was time to take the cars out of hibernation. The /6 was on top of the lift and the red flared car was under the lift. I got in the red car and noticed the WAS top was all but shattered. I pulled the car out of the garage and noticed it was wet. Apparently the master cylinder failed in the top car and emptied all the brake fluid into my drip pan, which eventually leaked.

Besides the WAS top getting demolished, we all know what brake fluid can do to paint. I took it to 2 different body shops and am waiting for estimates. So far for paint it will need the hood, right front fender, passenger door, windshield frame, rear fender and rear deck lid.

Today I got under the /6 and removed the 23mm master cylinder thinking the internal rubber seals had failed, but I don't think so. The grommets from the reservoir were damp. Upon removal I noticed neither of the grommets had the REQUIRED washer under them. I think it was just a lack of experience as to why they didn't get installed because they are 62 cents a piece at Stoddard (http://www.stoddard.com/90135593600.html). Why it failed over the Winter is a mystery as the temperature in the garage never gets below 45 degrees.

There are several lessons to be learned here.

#1 - If you don't know what you are doing don't do it, especially when it comes to brakes.

#2 - Bulletproof your drip trays if you are storing a car underneath another one...

#3 - Have good insurance even when stored in a garage.