Intro from Montana: '73 2.0L rustoration thread Options

[bbrock]

Am I done with these fuching brakes? I sure hope so. I contacted Mark about the weeping MC. Turns out they've had a small number from the first batch that did the same thing. Because that plug isn't ever under pressure, the leak didn't show in the original pressure tests they ran on the MCs but now they know to test for them as part of their QC checks. He said I could try repressing the welch plug myself and he would give me store credit to compensate for the hassle. If that didn't work, he would replace it. So that was my day yesterday.

First, let me say that installing an MC on a fresh new and dry system with the car raised high isn't exactly easy, but it isn't bad. Removing and replacing an MC after the system is filled with fluid is a shit show. I filled several swear jars before the day was over and this was with plenty of room under the car to work. I don't know how anyone does this with the car just up on jack stands. Okay, enough bitching. On with the show.

Here's the MC after pulling. That welch plug is the culprit. Hard to see in these pics, but it was slightly cocked in the bore when press. Also, I think the dye used to press was too large of diameter. Welch plugs are domed so that when pressed in, the plug is simultaneously pushed down and flattened out to squish the edges against the bore for a tight seal. Pressing only around the perimeter doesn't apply much flattening force.





Before trying to correct this, I needed to be able to test the leak. This was easy enough by filling the MC with brake fluid and then applying about 2-5 psi of compressed air to each inlet port while plugging the outlets with my finger. Applying pressure to the front circuit quickly showed fluid bubbling through the plug making it easy to test if I was successful.

To fix it, I started by using a 7/16 socket in a vice to better seat the perimeter of the plug in the bore. 7/16" just fits inside the bore and closely matches the original dye used.



Then I repeated this with a 5/16" socket to apply force toward the center of the plug to get the flattening I think was missing on manufacture.



Here's how that looks after the re-press. The leak test was a success. Hallelujah!



As an extra precaution, I filled the well over the plug with JB Weld.



Spent the rest of the day cussing to put everything back together. Then bled the system again and let it set overnight with a clean paper towel under the MC. This morning there were two drops on the towel. Those were caused by slight seepage around one of the inlet grommets. I just wiggled and massaged the grommets and inlet tubes to better and think I fixed it. I'm not too worried about that but will wait awhile before putting the gravel pan back on. Here's hoping I'm finally done with these damn brakes!

[mepstein]

I gave a MC to Ben so he might want to look at it before install.
@MB911

[Superhawk996]

Don't let the setbacks get to you. You're making great progress.

[mb911]

Well I know I will now be checking mine before putting fluid in there for sure. Brent your experience will help others.. Thanks for sharing.

[bbrock]

Don't let the setbacks get to you. You're making great progress.

The setbacks alone don't really get to me. That's just part of a project like this. But they have put me way behind in an extra short summer in a place famous for short summers. We had snow through the end of June and now leaves are already starting to turn. I have a lot to do before I'm ready to paint. If I don't have the exterior in color before the weather turns, THAT will get me down. At the same time, I'm being very careful not to feel rushed because that will only lead to a crappy job. I just keep plugging and things will come together when they come together. (IMG:style_emoticons/default/beerchug.gif)

[Superhawk996]

Don't let the setbacks get to you. You're making great progress.

The setbacks alone don't really get to me. That's just part of a project like this. But they have put me way behind in an extra short summer in a place famous for short summers. We had snow through the end of June and now leaves are already starting to turn. I have a lot to do before I'm ready to paint. If I don't have the exterior in color before the weather turns, THAT will get me down. At the same time, I'm being very careful not to feel rushed because that will only lead to a crappy job. I just keep plugging and things will come together when they come together. (IMG:style_emoticons/default/beerchug.gif)

I feel your pain. I'm sitting here with my vacuum bagged neck leaking like a sieve and the vacuum pump buzzing every 2 seconds. I think by the time I'm ready to do any welding / chassis work on my back I will have lost 6 months.

If you had to you could pull off paint in the garage to extend the season. But either way, it is what it is. Don't rush paint, it never works out and it is THE thing that shows 1st if not done right!

I'll be wishing for an an extended Indian Summer for you!

[Dion]

Dude sorry for the brake debacle. Appreciate the know “how to fix “ info.
Hang in there man. Your progress is phenomenal.
We’ve all learned a lot. I’m not always posting a response here
but totally paying attention. Here’s to an extended summer for ya (IMG:style_emoticons/default/beerchug.gif)
Don’t rush to paint!
Cheers mate!
PS “ Superhawk” heal quick, wishing you well too.

[sixnotfour]

sorry ..but that is not how a welch plug is installed..
https://www.spriteparts.com.au/tech/welch.html

B. Installation
Plug sould be installed with a tool similar to that shown in illustration. Tool diameter D = 0.95 x counterbore diameter.
The tool should be designed to bottom out when the plug is flattened 30% or more of its formed height but never flattened completely. The amount of flattening must be established by the user depending on the tightness required of the seal consistent with other factors of the user's design.

[bbrock]

sorry ..but that is not how a welch plug is installed..
https://www.spriteparts.com.au/tech/welch.html

That does look better but I'd be afraid to do it on an MC for fear of breaking something internal. I was just following the instructions that Eric/PMB gives for installing welch plugs on rear calipers. I think it will be fine for this plug that isn't under pressure and better than the original install. At any rate, I'm not pulling that f'ing thing our again. (IMG:style_emoticons/default/biggrin.gif)

[bbrock]

Got the putty on the driver's side today.





Okay, now it's time to pucker my anus. This next step is going to be a butt clencher. (IMG:style_emoticons/default/unsure.gif)

[raynekat]

Brakes....what a mess, eh? Finally got my venting distances adjusted on the rear calipers, but have been unable to get the air out of the m/c or p/v in the rear. I'm getting a good flow of fluid without bubbles from each caliper, so the air must be elsewhere in the system. The m/c is new ATE, so hopefully there is not a seal issue?

Yeah, when Eric does the Welch plug on the rear calipers, he uses an arbor press that pushes in the center of the plug....not the perimeter. Maybe that was the issue with the 914 Rubber parts?

Body work is looking great and reminds me of mine a couple of winters ago....

[914_7T3]

Don't even think of rushing it! I know you'll regret it so just stay the course. You're doing great.

As you already know, everything takes longer than anticipated.

(IMG:style_emoticons/default/beer3.gif)

[bbrock]

Tranquility Base here, the Eagle has landed!

















Neil Young - The Loner (slightly modified)

[Verse 1]
She's a perfect stranger
Like a cross
Of herself and a fox
She's a feeling arranger
And a changer
Of the ways she talks
She's the unforeseen danger
The keeper of
The key to the locks

[Chorus]
Know when you see her
Nothing can free her
Step aside, open wide
She's a roller

(IMG:style_emoticons/default/shades.gif)

[TravisNeff]

Giddyup! (IMG:style_emoticons/default/driving-girl.gif)

[sixnotfour]

(IMG:style_emoticons/default/beerchug.gif) (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/birthday3.gif)

[Superhawk996]

(IMG:style_emoticons/default/beerchug.gif) (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/birthday3.gif)

(IMG:style_emoticons/default/WTF.gif)

Is today Brent's birthday? Same day as my wife. She got flowers.

Sorry Brent - you didn't get squat!

[sixnotfour]

914 B-day....back on all four...... (IMG:style_emoticons/default/santa_smiley.gif)

[Superhawk996]

914 B-day....back on all four...... (IMG:style_emoticons/default/santa_smiley.gif)

Oops . . . . slow on the uptake. (IMG:style_emoticons/default/slap.gif)

[dr.tim]

As you already know, everything takes longer than anticipated.

Even when you take into account Hofstadter's law.



Congratulations Brent! (IMG:style_emoticons/default/biggrin.gif)

[andrewb]

(IMG:style_emoticons/default/drunk.gif) (IMG:style_emoticons/default/drunk.gif) (IMG:style_emoticons/default/beerchug.gif) (IMG:style_emoticons/default/beerchug.gif) (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/piratenanner.gif)

Congrats from over the pond.