Brakes

What a pain!

How many times do you bang your head against a wall before they call you crazy? By 2021 I was on my 3rd master cylinder. First was the original German model, I swapped that in 2016, then again in 2021.  My problem was that its a single circuit system, when the brakes fail the FAIL.  Here is an article on Jbugs that really helped me understand the difference:

Single Vs Dual Circuit Master Cylinder

Fast forward to spring 2023, I tried to bleed the brakes to move the car, it would not bleed. I had my wife, my son,  my buddy Paul, all working the brake pedal for me. Nothing. Again, total failure. I figured if I was going to fix it, the only real way was to replace it all, but I did that already in 2016 and again in 2021, so what was the point?

Finally I understood what I was doing wrong, I realized another big mistake I had been making for a long time, thinking INSIDE the box. This car has a VW 1965 engine and transaxle. That's about the only thing that would be considered a 1965 VW... Some parts are from 66, some from 68 to 71. I think the frame itself is actually from a VW bus. I suspect this because when I attempted to replace the 1965 speedometer cable I was about 2+ feet short.

The car was manufactured in 1978 from MANY different VW parts, I didn't have to stick with the same master cylinder, it was time to change things up.

I ordered all new brake cylinders, soft lines, hard lines, line benders, cutters, everything I would need. I decided to put in a dual circuit master cylinder and try again. This was not an easy task. I could not just slap the parts in, getting to some of them required removing bolts and parts that had not been touched in over 50 years. I had to remove the drums, not an easy task when the wheel bearings are part of that equation.  This is the reason I didnt go full disc brakes, I wanted to try to keep it as original as possible. 

I had to buy a breaker bar and a 32MM socket. The socket was not easy but I found it. Took the old cylinders out, put the new ones in, installed the new brake lines and connected them to the new master cylinder. I ordered a larger reservoir and bled the system Boom I had brakes and I now know if the master cylinder does fail, it will most likely only fail on one circuit allowing me to stop and ultimately replace the master cylinder. I took care when I re-did the gas tank to make it easily removable to make the master cylinder accessible.  It drives and more importantly stops very well now!

The Old System

New Brake Reservoir

Old Wheel Cylinder

Old System