Hi...just looking into the practicalities of converting to servo-assissted brakes, using Brazilian bay parts... Aside from the obvious components (see below), does anybody know what additional parts will be necessary? Servo unit & mounting bracket Master cylinder and reservoir Hoses, fasteners and couplings Manifold take-off Does the stock (non servoed) brake pedal need to be modified or is there sufficient adjustment in the pushrod, to suit? Thanks in advance....
Same pedal, you might have to extend the new push-rod by an inch, or might not. You do on earlies, might have to on crossovers and don't think so for lates. Non-return valve and Extend wiring to brake switch(es) Brake lines I re-shaped what was there last time without even making off any ends and it came out very neatly if I do so so myself. You might as well make the bracket for the beam from scratch - for the brazillian servo mounting stud pattern the holes would all be half off the edge of a og bracket.
Didn't have you pinned as both Sexist and Legist Joker.... Thanks @zed ...there's a guy knocking universal brackets out on fleabay for £15 (bargain by my reckoning) Servo c. £80, M/Cyl c. £50 Reservoir, Non return valve, hoses, fluid etc. £80 + Hassle factor...moderate....All in for around £250 or thereabouts....cheaper if I can find decent secondhand bits @Dicky ...what bits dost thou haveth?
The brazil servo,a M/C, reservoir and non-return valve are about £155 at JK prices. £5 for a manifold fitting £20 for a push rod £30-£40 for pipes and clips? £220 DIY is as cheap as chips. It's making the bracket, extending the push-rod that takes the time, and painting them, re-routing brake pipes and refixing them, extending the pipe between reservoirs, running the vac hose (I forgot grommets £4 - best route is through the two cross-members), removing the carb/manifold to fit the fitting (don't forget a new gasket), rebalancing the carbs, re-routing the wiring and bleeding the brakes. A day and a half to make a nice job of it. A day to slap it in.
I have a 2nd hand late servo (which may work or may not!) If I recall it has push rod and master cylinder attached to it and has been stores in my garage ....forever! Bought as a second hand good one when they were hard to come by. I recall paying over the odds for it and then fixing the problem without using it. Is it worth rebuilding a master cylinder for the cost though. Brazil servo and m/c seems very cheap and... much newness. Think progressive manifolds have servo takeoff as standard but could be wrong!
Ooooh!....bet you're going to get some PMs after announcing that @Dicky ....Rebuilding a M/cyl is pence by comparison...I'll have a moochy on the net about refurbing Servoes...are you interested in parting company with it....or should I switch to covert conversation mode?
My own one - I got a servo and m/c with reservoir on ebay for £45, some pipe etc and did the job for less than £100, the manifolds had a balance pipe which I tapped into for the vacuum. But the master cylinder started leaking after a few months and had to be replaced. With hindsight I'd go for new bits as they're not very expensive.
mk2 golf non gti servo and master cylinder £20 of ebay have a long pushrod made servo to pedal to suit lenght by local machine shop, plastic plumbing hose from diy store for vacuum pipe front to rear, 1 way valve from scrap yard and rubber vac hose from motor factors and your done £50 and a bit of elbow grease and your sorted
And the reservoir connection pipe. When it's all together like that chances are high it's a good one - you wouldn't scrap a van because it had brake problems.
