How to: Install power brakes into 1968-1970 Bus (Pic heavy)

[Koeppler]

[KTPhil]

I believe he cuts and welds in an extension. Be sure to start with the right rod.

[NASkeet]

Automec DOT-5 Silicone Hydraulic Brake & Clutch Fluid Leaflets

This is the Automec DOT 5 silicone hydraulic fluid with which I filled the modified hydraulic braking system of my RHD 1973 VW 1600 Type 2 Westfalia Continental motor-caravan during the winter of 1988/89 and the hydraulic clutch system of my RHD 1974 BLMC Triumph Toledo 1300 "HL Special" in late-1987.

https://www.thesamba.com/vw/archives/manuals/automec.php

IMI Yorkshire Alloys Kunifer-10 brake tubing

When I retro-fitted the pair of ATE - Alfred Teves, remote-acting, vacuum brake-servo units and replaced all of the rigid hydraulic pipework on my RHD 1973 VW 1600 Type 2 Westfalia Continental motor-caravan during the winter of 1988/89, this is the Kunifer-10 alloy (i.e. 90% copper & 10% nickel) tubing that I used; requiring about one and a half 25-feet lengths.

Charles Bulmer, “Arresting Developments”, Car Design & Technology, Issue 5, December 1991, Pages 82~84

One of the important things highlighted in the following article, is that water enters the hydraulic fluid by diffusion through the semi-permeable, flexible hydraulic brake hoses, rather than the vent in the hydraulic fluid-reservoir cap!

Peter Noad, “Fluid Dynamics!”, VW Motoring, October 1999, Pages 66~69

_________________
Regards.

Nigel A. Skeet

Independent tutor (semi-retired) of mathematics, physics, technology & engineering for secondary, tertiary, further & higher education.

Much modified, RHD 1973 VW "1600" Type 2 Westfalia Continental campervan, with the World's only decent, cross-over-arm, SWF pantograph rear-window wiper

Onetime member, plus former Technical Editor & Editor of Transporter Talk magazine
Volkswagen Type 2 Owners' Club (Great Britain)

https://vwt2oc.co.uk

[D/A/N]

I’ve accumulated almost all the parts for adding a booster to my 70 and am curious about getting the rod lengthened. Before I get it done, can someone explain why it needs to be lengthened in the first place? Since the pedal is the same over the years and the beam mounts in the same place, what about putting a booster in an earlier bay requires the rod to be lengthened by an inch?

Not doubting, just trying to understand.

[kreemoweet]

[D/A/N]

[aeromech]

I’m the OP and now I’m going to say it again. Lengthen the rod by one inch if you want to do the booster installation the way I did it
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[mack00]

I'm starting the install of this mod on a 69 single cab with aftermarket front disc installed. I see its recommended to run a single brake line from mc to a tee and then split to left/right on the front brakes. Would there be any advantage to running individual lines from mc to front left/right calipers? Not sure if the disc calipers require more volume compared to the original drums.

[aeromech]

No
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[busman78]

Back on the first page a question was raised by Desertbusman about the feasibility of using Gates 27231 hose with brake fluid -

I'd take issue though with using that particular Gates hose for the refill line. Very slim chance it's brake fluid compatable. Because someone has used it and a year later it's still working doesn't make it good. A vacuum application has nothing to do with a brake fluid application.
The difficulty is that tracking down a Gates product listing is about impossible. It's probably more difficult that getting Parker hose tech info. But the bottom line is that very very few hose materials are listed as acceptable for brake fluid use. EDPM is a material that usually is on the good list. Plain vinyl hose or rubber hydraulic hose isn't. We've gone thru the "reservoir refill hose" topic a few times and the bottom line is always stick with the clear original line and specialty end seals that VW used. The only acceptable rubber hose is the VW Blue hose specific for brake fluid use, unfortunately it's the wrong diameter for what you are doing. I'll keep an eye out for Gates brake fluid compatable hose. Unless their spec sheet says so the 27231 is not good.

I contacted Gates tech department and received the following about the hose makeup -

EPDM Tube, Synthetic Fiber Reinforcement, EPDM Cover

Since EPDM is the preferred rubber for brake fluid I plan on using it as a resevoir hose.

[sodbuster]

Or this. $11.99 a foot. But what's the skin on your ass worth to you?
https://socalautoparts.com/product/hose-brake-blue...gK8_fD_BwE

[busman78]

I would like to see that blue hose stretched over a 12mm fitting. The resevoirs are 12mm, VW used a plastic type tube with a rubber bushing and clamp originally, the only place I have found that tube for sale is at Heritage in England, it also is not preformed and a pain to bend without damaging. Having a flexible rubber hose that will tolerate brake fluid in 12mm is a blessing.

[aeromech]

Using the gates. I have a customer from 12 years ago and no problems yet
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[Koeppler]

[aeromech]

The 1971-1979 master cylinder has two outputs (circuits). One goes north and one goes south. Each of those hits a tee which splits the fluid to left and right.

The early 1968-1970 master cylinder has two front ports, one goes to left front and one goes to right front. The newer model MC requires a tee as pictured.
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[rhodsdon]

Before I weld the new booster mounting plate to the beams I have a question about the angle of the brake pedal push rod. The old master cylinder mounting is angled toward the brake pedal lever so the push rod is straight in line. It is not square with the beams. While the angle is not very much, if I weld the mounting plate square on the beams the push rod will be somewhat angled toward the pedal assembly.

Comments? Should I square the mounting plate with push rod? Tweak it slightly to line up better. Or is this no big deal with enough play in the connection to foot pedal lever?

[rhodsdon]

If someone is stilll looking for 12mm reservoir hose compatible with brake fluid McMaster Carr has 1/2 EPDM for $2.20/ft.

https://www.mcmaster.com/catalog/130/292/5304K26

[metahacker]

i was browsing some parts and saw this...made me think of this awesome thread gary made..and how some people studying it might find this useful

https://www.slaughterhousecustoms.com/product-page...-1967-1979

basically a full kit to retro a booster onto a non BB bay (e.g. '68-70)

i assume the BB bracket is like the one limebug sells, bolt-on (rather than welded)

hope this helps someone ;)

[aeromech]

It’s a good visual guide for what’s needed but I’ve never seen a red booster sold and wonder about its quality. ATE made original boosters and once rebuilt I think they are the best compared to the Chinese ones sold widely which people seem to have trouble with
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound