Archive for the ‘disc brakes’ Tag

Type 65 Coupe Project Update: Preparing for Engine Installation   1 comment

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I spent the last two weekends in the garage, getting back to the Coupe Project. It was nice and relaxing to lay on the creeper, under the chassis and working with tools again.

I had to modify the chassis in the pedal box area to allow more clutch pedal movement. This is a known issue in the Roadster forums, but not so much in the Coupe forums. This happened when Factory Five Racing changed the Wilwood pedal box – the old version would actually break. The new and improved pedal box moves the clutch pedal arm over to the left by about an inch or so, and the arm hits a brace, limiting pedal travel.

When the modification is done before the pedal box is bolted into place, it is a simple chore to make two cuts, chopping a small triangular cut into the frame member. This can be done with a reciprocating saw or maybe power jigsaw.

However, if the modification must be performed after the pedal box is bolted into place, the tube must be accessed from below, in an awkward angle. A small grinder tool would be ideal for this, but the only tool I have that will fit the space and the angle is a Dremel tool. It took me two half-day sessions to do this.

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In the pictures above you can see the half-moon shape cutout I had to make. This is a view from under the chassis, looking up from the creeper. This will be painted black later. The tube looks normal from the top, so that is good. And clutch pedal travel is doubled, so free play adjustment range should be much better.

Since the brake system is installed, filled and bled, I removed the Clekos and riveted the lines in place. I changed several P-clip anchor points so it complies with my “routing and clipping manual” from the office. Unfortunately, I followed some other builders’ clipping, and mounted several p-clips upside down. Most of them will be under the car, and might be hidden from view when the car is finished. But I know they are upside down.

Here is a picture of how the clips should be mounted. This is the X-member in the front of the chassis.

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Looks like I didn’t take a picture of the riveted clips. I will post them later.

Next, I made a bracket to support the ECU for the MSD Atomic fuel injection system for my 302. This plate will secure the ECU and provide strain relief for the cables going in and out of the unit. It is on a plate so it can be easily removed if I have to work on the wiring or the ECU later. It is mounted with 1/4-20 stainless steel studs and nylon lock washers. It was raining so I was not able to paint this plate. Will have to do that at the next build session.

The passenger side footbox is on the left. Three stainless steel Allen head screws come through the wall and into the passenger box. The center photo shown the ECU engine cable going into the engine bay, and the right photo shows the MSD computer and plate inside the passenger footbox. Carpet will cover the interior, so a carpeted cover will be made to hide the ECU and wires when the car is finished.

I am also laying out the air conditioner system components on the chassis. I have to make several brackets and small boxes to mount the A/C components on the chassis.

As I was doing this work, I took another look at the battery box mentioned in an earlier post. It is installed with clecos so it can be removed. I think I want to mount the battery above the passenger footbox. Two reasons for this:

First, it will shorten the battery cables, decreasing the voltage drop.

Second, the “factory location” for the battery – in the rear center – blocks the rear axle pumpkin. So, when I have to change the oil or make adjustments, the battery must be disconnected and the battery and the box must be removed. Sounds like a painful procedure for a simple maintenance chore.

I will make a mock-up of this in my next build session. Stay tuned . . . .

 

 

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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.

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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.

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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!

 

 

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 Update: Brake Line Mock-Up   Leave a comment

For some reason, things on the Coupe take much longer than I expect. I decided to practice running the brake lines today. I used some scrap number 12 wire, cut into five-foot lengths. The copper wire is much more flexible than the brake lines, but at least I can do a mock-up before I bend the real thing.

I am using the “FFR Type 65 Coupe build site,” by cbergquist1 on Flickr.com as a reference – click here to see Chris’ section on brake lines.  http://www.flickr.com/photos/51103049@N00/sets/72157622122325431/

Just like Chris, I drilled and tapped holes for screws to mount the flex brake line mounts. I used 8-32 stainless steel button head screws. The Allen heads almost look like rivets.

Here are some pictures of my front brake line mock-up. . .

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This is something weird. One of the mounting holes was not punched out. I used an automatci center punch to knock the slug out.

This is something weird. One of the mounting holes (on the left) was not punched out. I used an automatic center punch to knock the slug out.

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I took a time out to modify some monitor stand mounts for my office computer. The mounts were designed by monkeys, since they are useless and cannot be used out of the box. Actually, I should edit that statement, since I am not sure if the monitors or the monitor stands are wrong. In any case, some substantial cutting had to be done with my Dremel tool. I should have taken “before” and “after” pictures, but I wasn’t thinking. Here is a picture of the after-cutting operation. . . .

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Type 65 Coupe Update – IRS Brakes   Leave a comment

I forgot to add notes and images from the IRS (standard width) brake installation. Here are some images, plus a link to a YouTube video…

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As you can see in the picture above left, an open end wrench can go onto the caliper mounting bolt. This was a button head Allen screw in the past. The emergency brake cable seems very tight and has a sharp bend, but this seems to work OK.

 

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The vintage Halibrand replica wheels fit nicely over the axle-hub-brake assembly, but I don’t have tires yet.

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The rear wheels are 17-inches by 10.5-inches, and the tires will be 275 / 40ZR17, probably BF Goodrich g-Force Sport Comp 2, but not sure yet.

A Silent Movie: Rear Brake Installation

Oh – almost forgot. Here is a silent movie about the rear brake installation:

http://www.youtube.com/watch?v=bVcX8-Nnqfo

 

Type 65 Coupe Update: IRS Brakes   2 comments

Not much Coupe time this weekend. The rear brake adapter plates and spacers from Factory Five Racing finally showed up – Saturday delivery via FedEx.

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Since these are raw steel, I decided to prep and paint them, using gloss black Appliance Epoxy paint. They look much nicer now.

I removed the rear spindles from the last build session and did a dry-fit to see how these get assembled. Once again, the assembly manual and the actual assembly are different. Instructions say to use some button-head Allen bolts, but there aren’t any.

Here are some pictures of the “RH” side of the assembly to see how this goes together. The adapter plates are not painted in these images.

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I will bolt these components in place in the next building session.

A Color Decision

I decided to paint the engine bay white. I know this sounds scary, but after thinking about this for a while, it just makes sense. It will match the body color, it will have nice contrast against the black chassis and the engine and other components, and – I can use Appliance Epoxy, which is pretty durable and washable. I will be painting only the outside surfaces of the panels because all of the inside surfaces will be covered with Thermo-Tec Cool-It sound and heat insulation mat.