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Fri Aug 15, 2014 8:57 pm

I was asked to show how I changed my single circuit master cylinder to a dual circuit master cylinder

I am posting this " step by step " record on how I did this to my 66 bug

" this is not an instructional thread " DO NOT TRY THIS AT HOME... " Entertainment only..

remember
.ANY brake work should ALWAYS be done by PROFESSIONAL experts in PROFESSIONAL establishments professionally

This is how the single circuit master looks with the gas tank removed
Pink tape...old single circuit master cylinder
Green tape...old front hard ( metal ) lines
Orange tape...single brake warning light switch
Red tape...old rear brake hard line

The dual circuit master needs a second brake light circuit
I used the BLUE piggyback clips on the first switch and ran wires to the second switch with RED connectors

The single circuit master was removed by taking out the two bolts behind the brake pedal
I was VERY careful to not loose the round spacers that go around the bolts

I removed the old master AND the FRONT hard lines ( I thought it would be easier to order new 67 front hard lines and bend them into place

Dual circuit master bolted in place wher the old one came out ( no modifications )
Green tape ...two new 67 hard lines bent to fit
Red tape ...the old rear brake hard line attached to the new master WARNING...I had a lot of trouble getting this connection to fit I didn't want to cross thread the threads and RUIN the new master . I was VERY careful here

Two original brake light wires attached to the brake light switch on the blue piggyback clips
White arrow points to where I put a piece of blue tubing on the hardline where it crosses the tunnel
Pink arrow points to where I attached the blue brake fluid supply lines to an existing clip on the tunnel with tye wraps to keep them away from the steering
Shiny tool with red handle is a tubing bender

There are many ways I could have done the next step ..This is the easiest one to have cuz i wanted ease of checking and filling
I changed the small 66 brake fluid supply out for a dual circuit 67 style by enlarging the existing hole in the front clip and making a hold strap out of 20 guage sheet metal { 1/2 inch wide x 11 1/2 long }
The blue tubing is not affected by brake fluid

GEE I HOPE I DID THIS RIGHT

remember
ALL brake work should be done by a qualified PROFESSIONAL in a PROFESSIONAL establishment Professionally

Sat Aug 16, 2014 6:56 am

grandpa pete wrote:

Looks good Gpa. :D A little tip for you, for when you decide to re-install the pedal cluster. Either drill 2 holes in the end of the hook for the clutch cable end, and add some mechanics wire to bridge the gap (prefered method), or use a bread tie to tie the cable end to the hook. That way you won't have the cable fall off the hook when re-installing the pedal cluster. I'm only mentioning it, as I know you like to work alone (as do I). :wink: I hope this helps.

Sat Aug 16, 2014 7:16 am

Thks bobnotch ; Blue hose loop IS flat.....I'm glad your keeping an eye on this...somebody has to keep me on the straight and narrow :)

Sat Aug 16, 2014 7:23 am

That is exactly the way I did it. I had a master cylinder go bad and when I checked the reservoir one side was empty, very simple

Sat Aug 16, 2014 10:11 am

Just wondering if the old washer reservoir will still fit in the space when the new, 67, reservoir is installed.
Thks for posting the procedure.

Sat Aug 16, 2014 11:22 am

Apply some grease, anti-seize or silicon grease to all the threaded brake line ends. Work the nuts on the ends of the brake lines back a bit and grease up the brake line where the nuts seat around. This will help to keep moisture away from the nuts and rust away for as long as possible. So nice to go back for repairs many years later and not have to fight rusted nuts from each cylinder or twist up the brake lines due to the nuts rusted to them.

Brake lines only seal at the very tip of the lines so wipe off any excess grease or anti-seize from there to keep from getting into the system, or use only the silicon grease which should be used on any rebuilt brake cylinder on the inside to lube up the pistons seals and cylinder bores.

Sat Aug 16, 2014 4:17 pm

pwmcguire ; did you use hose clamps where the blue hose joined the copper lines out of the fluid reservoir ?

Sun Sep 14, 2014 9:39 pm

any body else ; ...hose clamps on blue line where they go on copper lines from resevoir

Sun Sep 14, 2014 9:52 pm

There is very little pressure there, so does not need clamps. The rubber plugs that hold and seal the brake lines pipes or reservoir type mounted directly to the dual MC are only snapped into place.

Mon Sep 15, 2014 7:54 am

Thanks for the thread Grandpa. I will be doing this upgrade when I get my bug back from Tom. Still waiting patiently.

Mon Sep 15, 2014 5:13 pm

Timely for me too!
Thanks Grandpa

Mon Sep 15, 2014 5:26 pm

grandpa pete wrote: pwmcguire ; did you use hose clamps where the blue hose joined the copper lines out of the fluid reservoir ?

Yes because it was not a tight fit at all.

Fri Oct 10, 2014 7:18 am

NOTE : I did put hose clamps on the blue hose where it connects to the brake fluid reservoir .

Fri Oct 10, 2014 6:35 pm

Great write-up. Thanks

Sat Oct 11, 2014 2:06 am

THANKS SO MUCH!

Sat Oct 11, 2014 5:09 am

Use the master mounted reservoir... no hoses required. :wink:
.

Sat Oct 11, 2014 7:08 am

VOLKSWAGNUT wrote: Use the master mounted reservoir... no hoses required. :wink:
.

Already explained that there were several ways to do the reservoir.....I chose the easiest way for the old guy to check AND refill

Sat Oct 11, 2014 9:13 am

grandpa pete wrote: VOLKSWAGNUT wrote: Use the master mounted reservoir... no hoses required. :wink:
.

Already explained that there were several ways to do the reservoir.....I chose the easiest way for the old guy to check AND refill

Yeah ok.. :roll:, but I call BS on the whole old guy excuse though....

.

Sat Oct 11, 2014 9:25 am

:P :P

Good Boston Irish stock !!

Dad made 84

His Dad did 95

Got to think long term :wink:

Sat Oct 11, 2014 12:58 pm

grandpa pete wrote: :P :P

Good Boston Irish stock !!

Dad made 84

His Dad did 95

Got to think long term :wink:

Same here, dad lived till he was 88
Irish too.