Archive for the ‘brake reservoir’ Tag

Type 65 Coupe Update: Some Air Conditioner Work, Re-Installing the Firewall and Red Brake Lines   Leave a comment

Not much to report on the Type 65 Coupe Project. I have been doing a lot of other things over the last few weeks. The heat has been making me lazy.

I decided to do some work on the A/C unit for the Coupe. I cut and chopped the housing cover for several hours, and then decided it might be easier to just make a whole new cover using fiberglass and resin. . . . I did some research on composites, epoxy resins, fiberglass and boat repair, and lost-foam casting. Interestingly, I am doing the same research for some stuff at work. I will try my hand at making a custom duct for the A/C unit. I have a layout in my mind, but there are a lot more things that need to go behind the dash panel besides the A/C ducts. The new cover/duct will have to make several 90- and 180-degree bends. I hope to avoid the use of too many fittings by making a single duct/top cover for the A/C unit. Maybe it should be called a “manifold” instead.

Here are some pictures of the air conditioner and the “dry fit” of where it will mount.

IMG_0597 wayne yoshida Coupe AC 2

IMG_0599 wayne yoshida Coupe AC 3

 

I also re-installed the firewall. I had to take it off and re-paint it with a higher quality silver paint. I do not have pictures of this, but it does look better than before. The paint is “harder” than the other paint I used.

Next, I removed the “bad” brake hoses originally from the Complete Kit and replaced them with the proper red hose from the third technical bulletin from Factory Five Racing. This is the hose going from the reservoir to the master cylinders. The new hose is much softer and easily slipped over the fittings. I hope they won’t leak. We will find out soon when I fill and bleed the system.

IMG_0600 wayne yoshida Coupe - BAD brake lines1

 

IMG_0601 wayne yoshida Coupe - band brake lines2

 

IMG_0603 wayne yoshida new red brake lines 1

I also started to look at engine hoist options – I want to drop the engine in SOON!

 

 

Advertisements

Type 65 Coupe Update: Disc Brake Plumbing   Leave a comment

It’s been a long time since I posted an update on the Factory Five Racing Coupe. Here is an update in pictures and captions . . .

Back to the Coupe Project: Brakes and Goodies from Russ!   Leave a comment

Where does the brake reservoir go?

Where does the brake reservoir go?

Before I drill any holes, I need to verify where the brake rez can should go. This polished stainless steel can looks great, and it is small. It must be easily accessible for filling and must also be higher (at level with) the brake master cylinders.

Location of the brake rez here or there?

Location of the brake rez here or there?

A few weeks ago I received a box of accessories from Russ Thompson, expert maker of Coupe add-on items. Here are some pictures. . .

Type 65 Coupe Project Update: Those Heat Shields, Rivet Nuts, Pedal Box and Accelerator Pedal   1 comment

Since the engine is in the middle of my garage, I really need to accelerate my building, or at least, get my chassis ready for engine installation.

I looked at my cookie sheet heat shields and the mounting locations filled with 8-32 riv-nuts, and thought – shoot, the riv-nuts actually have a shaft that might be used as stand-offs for the shield plates.  So I checked the length, and the threaded shafts are about a quarter-inch long, enough to be used as a spacer between the firewall and the heat shield. I may add another quarter-inch in certain places, if there is room.

So I spent a few hours removing all of the riv-nuts I installed a few weeks ago. Good thing I bought several hundred from McMaster-Carr. . . .

At least I am an expert on installing and extracting riv-nuts now.

Rivet Nuts and the Rivet Nut Tool

Here are some pictures of the riv-nut tool from McMaster-Carr and how it is used. Riv-nut fasteners are very handy if you need a threaded hole installed into a blind location, or when you do not have access to the back side of a mounting surface. I will use these fasteners for hatches and compartments in the trunk area of the Type 65 Coupe.

McMaster-Carr information

Wrench-drive rivet nut installation tool for 10-24 and 10-32 thread: 96349A203

Wrench-drive rivet nut installation tool for 8-32 thread: 96349A152

Wrench-drive rivet nut installation tool for 6-32 thread: 96349A101

Aluminum heavy-duty rivet nut, 6-32 internal thread, .080″-.130″ material thickness, packs of 25: 94020A315

Aluminum heavy-duty rivet nut, 8-32 internal thread, .080″-.130″ material thickness, packs of 25: 94020A323

Aluminum heavy-duty rivet nut, 8-32 internal thread, .020″-.080″ material thickness, packs of 25: 94020A319

kh6wz 010-riv-nut tool kh6wz 009-riv-nuts

kh6wz 013-riv-nut tool kh6wz 014-riv-nut tool

kh6wz 015-riv-nut tool

  kh6wz 017-riv-nut tool removing

kh6wz 019-riv-nut installed  kh6wz 018-crooked riv-nut

Above left – a picture of a properly installed riv-nut, viewed from the reverse (back) side. At right, a riv-nut improperly installed, viewed from the face (front) side. This one must be removed by drilling the riv-nut out. Below left, use a twist drill slightly smaller than the mounting hole, in this case, a 1/4-inch bit is being used to drill out the riv-nut. By slightly rocking the drill, the riv-nut will break apart and, usually, just fall out of its hole.

kh6wz 003 - removing riv nuts  kh6wz 004 - removing riv-nuts

Give Me a Brake: The Wilwood Pedal Box

The pedal box is a challenge to install with the Factory Five Racing Assembly Manual, revision 3E, July 2011 – since there are no assembly instructions for the Wilwood Complete Kit pedal box.

Fortunately, a dedicated Type 65 Coupe builder named Chris has an excellent photo album of his Coupe build, with many detailed images. Without his documentation – it would have been impossible to assemble this part of the kit. Take a look at cbergquist1’s photostream on Flickr.

 Here are some pictures of my pedal box, including a trouble spot I ran into, and how I had to fix it. . . .

kh6wz 006- coupe pedal box  kh6wz 005-coupe pedal box adj masters

kh6wz 015-coupe pedal box

This is the clutch quadrant adjuster (above). This Nylok had to be ground down to fit properly. The hole in the adjuster plate is too close to the master cylinder mounting plate.  A better solution would be to eliminate the Nylok altogether and thread the small plate. Then the lock nut and Allen bolt are used to make clutch travel adjustments.

kh6wz 016-coupe pedal box  kh6wz 017-coupe pedal box

Now I have to find a place to mount the master cylinder reservoir. There are some rare posts about this, but most of them are for the Factory Five Racing Roadster.

I think I will mount mine at or near the peak of the driver’s side footbox/firewall. This location should be away from too much heat, and should be in the clear for fluid bleeding, checks and re-filling. We will see. . .

The Gas Pedal

kh6wz 007-coupe accelerator pedal parts  kh6wz 009-coupe accelerator pedal

kh6wz 010-coupe accelerator pedal  kh6wz 011-coupe accelerator pedal

kh6wz 012-coupe accelerator pedal  kh6wz 013-coupe accelerator pedal

Part of the pedal box area is the accelerator pedal. Again, instructions are very skimpy on how to put this thing together. Here are some pictures of the gas pedal parts and how to dis-assemble the unit as it comes out of the box, and where it mounts onto the firewall area. Adjustments for the pedal box and accelerator pedal will happen later.