Official Mexican / Brazilian Beetles - All years

[hopkin]

I go out a see if I can get some measurements later this afternoon.

I haven't worked with brake fluid before, I do know it's toxic and will peel the paint off your car, so be careful.

I found this document in a quick search, maybe something helpful for you here:
http://www.mg-tabc.org/library/vw_master_cylinder_conversion.pdf

Also the PN for a new reservoir is 113-611-301-L is it widely available.

EDIT: I just took a picture and measured the length of the slot:

The slot measures 15mm. It was quite difficult to get the calipers in, I couldn't measure the width, or the distance from the side.
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1971 Super Beetle (past)
1971 Super Beetle (past)
1974 SunBug (past)
1972 914 (past)
1991 Honda Civic (Original Owner)
1996 'Open Air' Mexican Beetle (current)
2015 Golf (current)
2017 Dune Edition (daughter's car)

[GArBa]

thanks hopkin for the clear info & pic

unfortunately I may have to scrap the plan...
found out a source stating that a brake fluid level warning light is/was legal requirement in italy when my car was registered. (of course, speaking of "legal requirement" and "italy" everything is a bit blurry )

thinking about it, the only advantage I can see in converting the reservoir to a mk1 golf unit seems to be the brake fluid level sensor, and if you remember my first thread here on thesamba, on my car the brake switch singal wire was disconnected from the warning light and just the level sensor hooked up... I'm afraid I'll have to live with this mod.
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cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
-------------------------
moped:
'82 Benelli Magnum 3v

[hopkin]

[GArBa]

no, i just have the usual light on the right of the speedo, but I converted it to a dual purpose light.

From the factory, it would light up when you depressed the brake pedal and have one failed circuit.

As it was (modified) in my car when I bought it, it would light up when the brake fluid dropped below the "minimum" mark in the reservoir. (the signal wire for the original function was disconnected and covered in cloth wrap, so the factory function was lost)

I made a connector with two diodes (see here, now modified to get rid of the scotch-lock, see here) so that now mine can light up in both situations. if it lights up when I depress the pedal, I know there is a failure in one circuit (e.g. a air or vapor bubble); if it lights up without touching anything, the fluid level is too low. It is safer, because the level sensor is always hot, so if there's a leak the light can come up even when the car is not running.
_________________
cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
-------------------------
moped:
'82 Benelli Magnum 3v

[hopkin]

Nice job, I'd leave the reservoir as it and see if you could 'improve' the cut in the tray. You may be able to widen the cut, or maybe some type of rubber gasket where the hose rubs.
_________________
1971 Super Beetle (past)
1971 Super Beetle (past)
1974 SunBug (past)
1972 914 (past)
1991 Honda Civic (Original Owner)
1996 'Open Air' Mexican Beetle (current)
2015 Golf (current)
2017 Dune Edition (daughter's car)

[GArBa]

[hopkin]

I was looking for some images of the reservoir to see if there were any mounting tabs that you couldn't see. From this pictures I found, there doesn't appear to be any.

I found this link that shows the reservoir mounted directly to the master cylinder on the MKII:

http://workshop-manuals.com/volkswagen/golf-mk2/ru..._cylinder/

Zip ties are not a good solution, as they would degrade when exposed to the brake fluid. You may be able to fashion a metal strap that goes around the reservoir.

I found this part number, 533-611-301, for the reservoir and it appears to be discontinued.
_________________
1971 Super Beetle (past)
1971 Super Beetle (past)
1974 SunBug (past)
1972 914 (past)
1991 Honda Civic (Original Owner)
1996 'Open Air' Mexican Beetle (current)
2015 Golf (current)
2017 Dune Edition (daughter's car)

[GArBa]

what I have is a 867 611 301 B, MkI golf. I already have a spare one so I know pretty well how it's made. No mounting tabs as it is too mounted directly on top of the MC. I've already started designing a metal retaining "harness", I was thinking two brakets on top of the reservoir bolted down to a structure embracing the tray from the trunk side.
_________________
cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
-------------------------
moped:
'82 Benelli Magnum 3v

[GArBa]

I was thinking... would the golf reservoir fit if mounted directly on the mexican mc? if so, that would remove a lot of problems... maybe Antonio or Bruce know the answer?
_________________
cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
-------------------------
moped:
'82 Benelli Magnum 3v

[hopkin]

Funny I thought the same thing when I read your post. Antonio had previously posted this picture of the Master Cylinder. Unfortunately there are no measurements, but it give you a good idea of what it looks like.

I don't think the Master Cylinder has changed over the years, maybe someone has an old (not working) one that they could loan (or give) you to do some measuring and mock-ups.

_________________
1971 Super Beetle (past)
1971 Super Beetle (past)
1974 SunBug (past)
1972 914 (past)
1991 Honda Civic (Original Owner)
1996 'Open Air' Mexican Beetle (current)
2015 Golf (current)
2017 Dune Edition (daughter's car)

[GArBa]

checked on the parts list for the mexi.. grommets are 12mm internal diameter while golf reservoir has 8mm outlets...
_________________
cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
-------------------------
moped:
'82 Benelli Magnum 3v

[Bruce]

Look at Volvos. I know many guys around here have installed the reservoirs from junked Volvos straight onto their master cylinders.
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[GArBa]

thanks Bruce! I've made a search on thesamba using "volvo" and found out a volvo 240 res has 12mm outlets, will fit on the MC and it can likely take the cap with the sensor directly from the golf reservoir I have... I'll double check to be sure what master cylinder I have and then most likely go down this way!
_________________
cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
-------------------------
moped:
'82 Benelli Magnum 3v

[GArBa]

well for the sake of future reference, while researching this issue by browsing the 1978-on parts catalog on the vw classic website, I found out that for a short period VW of mexico actually installed 867 611 301 B on top of a 7-mm inlet master cylinder without provision for the dual switches. after that, they reverted to the dual switch activated warning lamp. (edit: too much uncle scrooge and too few mexi beetles on this page... )
_________________
cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
-------------------------
moped:
'82 Benelli Magnum 3v

[hopkin]

Garba: I was thinking of what problem you are trying to solve.

I like the idea of the low brake fluid warning, as well as the dual circuit warning, as you currently have things configured. And of course, if it's a requirement in Italy to have such a warning in place you should keep it.

Is the problem that the hoses to the master cylinder are rubbing on the 'tray' where the reservoir is currently mounted? Does the reservoir move around, as it's not fastened in place?

Just my opinion, but I like the idea of the access the current position of the reservoir provides, moving it to the master cylinder would make it difficult to top up.

For anyone else reading this, here's a photo of the reservoir Garba has (top image) and the stock one. The images don't show it but they are approximately the same length.

_________________
1971 Super Beetle (past)
1971 Super Beetle (past)
1974 SunBug (past)
1972 914 (past)
1991 Honda Civic (Original Owner)
1996 'Open Air' Mexican Beetle (current)
2015 Golf (current)
2017 Dune Edition (daughter's car)

[hopkin]

[GArBa]

[Gerrelt]

The previous owner of our beetle put a sticker or something on the glovebox door, and removed it later. Of course this left a ugly spot, where the texture of the door is damaged.
To cover it up, I've had a fridge magnet made with a safety warning on it which can be found everywhere Disneyland:

Sitting in the beetle will now feel like sitting in a rollercoaster!
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[hopkin]

That works

Do you know what caused those creases in the dash pad?

I used an old radio trim to clean up the edges around the cut out. I had to file the opening of the trim to fit the radio, but you can't see that part. It looks like it will cover the creases:

_________________
1971 Super Beetle (past)
1971 Super Beetle (past)
1974 SunBug (past)
1972 914 (past)
1991 Honda Civic (Original Owner)
1996 'Open Air' Mexican Beetle (current)
2015 Golf (current)
2017 Dune Edition (daughter's car)

[Gerrelt]

Those creases where caused by a very ugly radio the perious owner had installed. The radio was branded "Fiat".

This is what it looked like:

It was really ugly, I can't understand how somebody can have the cash to purchase a beetle like this, but cannot afford a decent radio..


Where did you get the radio trim? It looks excellent!
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homepage
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