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Dual Master Brake Conversion Reservoir.
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bluebus86
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PostPosted: Tue Sep 10, 2019 6:57 pm    Post subject: Dual Master Brake Conversion Reservoir. Reply with quote

I am considering a Dual Master Cylinder Brake Conversion in my 61 Bug.

What options are there for the reservoir? Id like to keep the reservoir in the trunk in the stock location, prefer a see thru container for ease of checking the level, and wish to retain the stock window washer bottle next to the reservoir. I recall some Volvo might work nicely, but dont remember exactly.

What options are there? Will someone provide photographs?

Thanks

Bug On! With Safer Brakes!
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PostPosted: Tue Sep 10, 2019 7:28 pm    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

1967 Beetle was dual circuit master. Reservoir is in the same place. WW has them new.
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wayne1230cars
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PostPosted: Wed Sep 11, 2019 7:08 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

IIRC the Volvo reservoir was a direct mount on the master cylinder similar to what CIP.com sells.
https://www2.cip1.com/ProductDetails.asp?ProductCode=VWC%2D113%2D611%2D301%2DDCC

I converted my 1960 to dual circuit master cylinder and used the 1967 reservoir method. It has worked well especially this spring when I had a major leak out of a front wheel cylinder.
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bluebus86
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PostPosted: Wed Sep 11, 2019 7:20 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

wayne1230cars wrote:
IIRC the Volvo reservoir was a direct mount on the master cylinder similar to what CIP.com sells.
https://www2.cip1.com/ProductDetails.asp?ProductCode=VWC%2D113%2D611%2D301%2DDCC

I converted my 1960 to dual circuit master cylinder and used the 1967 reservoir method. It has worked well especially this spring when I had a major leak out of a front wheel cylinder.


When i first got my 61 Bug, 40 years ago as a kid it had 155K mikes on it (Dad bought it new) driving to highschool the single circuit mater blew out. Had to drive home using the parking brake. Dad and me had just rebuilt the motor and tranny, but not the brakes.
It blew out while coming up to a red light, pedal to the floor, Yikes!

Since my brakes have an issue right now, I am thinking maybe now is the time to upgrade to a dual system. I also need to replace the link and king pins. I replaced them 40 years ago, that was about 180K miles ago, first set from factory went to about 155K miles. The tranny Dad and I rebuilt has lasted longer than the original, still good 155K miles verses 180Kmiles and still going strong. the old 40 Hp motor was replaced with a dualport 1600 maybe a decade ago.
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bigdog1962
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PostPosted: Wed Sep 11, 2019 7:35 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

Here's some reading and pictures. I have also done it if you need more pictures.
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wayne1230cars
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PostPosted: Wed Sep 11, 2019 8:45 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

bigdog1962 wrote:
https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

Here's some reading and pictures. I have also done it if you need more pictures.

Lots of good details in the above thread. http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=113611301H
Itís not a difficult job to do. There are 3 modifications to be done.
1) Enlarge the hole behind the reservoir sufficiently to allow the two reservoir outlet tubes to fit through.

2) Fabricate a longer retaining strap to secure the reservoir.

3) Use adapters to join the hoses from the 1967 reservoir (5mm) to the inlet hoses on the dual m/c (7mm). Some suggest cutting off the outlets on a plastic fuel filter and using that or buying brass reducer fittings. I used the reducer fittings.

Although not absolutely necessary, I removed the fuel tank to do this job. I changed all the metal brake lines including the front to rear. Fuel tank removal makes that job easier. Also changed the steering coupler while I was at it. It was likely original and was in bad shape. Good idea to check that.
Youíll need two brake light switches. I would opt for the better quality ones like WW sells.
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PostPosted: Wed Sep 11, 2019 9:57 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

If you want to retain it under the hood, in the original location and have it semi transparent to see the level.... the 1967 reservoir is the way to go..

You will have to make the retaining strap longer and you will have to open the sheet metal pass through hole for the double spout reservoir.
Use the correct brake fluid compatible flexible tubing and brake piping to connect the reservoir to the master cylinder.

Its all in here: https://www.thesamba.com/vw/forum/viewtopic.php?t=604177

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.





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wayne1230cars
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PostPosted: Wed Sep 11, 2019 11:33 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

This pic illustrates the direct mount reservoir. You drill a hole in the top of the reservoir and pop in a grommet. Then put the line from the original reservoir into the grommet. So the original reservoir look is maintained and essentially becomes like a funnel. You would have to check brake fluid level by looking through the wheel well area. Not exactly convenient.

So again, using the 1967 reservoir method would be my first choice for sure.
Image may have been reduced in size. Click image to view fullscreen.

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PostPosted: Wed Sep 11, 2019 11:45 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

There is actually a third option. Canít say that Iíve ever seen it done on a bug. You purchase a special bracket and brake lines and use the Ď68 and up reservoir. So fluid level is easy to check without having to remove spare tire.
Still like the Ď67 method.

https://www2.cip1.com/ProductDetails.asp?ProductCode=C31%2D809%2D021%2D111
https://www2.cip1.com/ProductDetails.asp?ProductCode=VWC%2D111%2D611%2D806
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PostPosted: Sat Feb 08, 2020 10:11 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

I have another option.
I use it on cars where you shoudn't see or smell anything other then "genuine VW".

Pictures are from a 65 I did last year, but it is similar to your 61.


Image may have been reduced in size. Click image to view fullscreen.

Reservoir on the right is from a T2b
Image may have been reduced in size. Click image to view fullscreen.

Simple 10mm adapter tube and common o-ring
Image may have been reduced in size. Click image to view fullscreen.

How it will fit
Image may have been reduced in size. Click image to view fullscreen.

Done!
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Any difference from original?


always aircooled

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VeeDee
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PostPosted: Sat Feb 08, 2020 10:28 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

A parts list for those who want to copy the conversation:

No. part number description

1 113 611 301 G fluid reservoir 1, upper, opened up for connector to 10mm
2 211 611 313 J fluid reservoir 2, lower
3 211 611 805 E tube, cut to lenght
4 211 611 833 D rubber gasket
5 selfmade connector tube 10x1x40
6 common rubber-o-ring 11x1
7 common tube clamp 12



Good luck

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PostPosted: Fri Mar 06, 2020 8:02 am    Post subject: Re: Dual Master Brake Conversion Reservoir. Reply with quote

VeeDee wrote:
A parts list for those who want to copy the conversation:

No. part number description

1 113 611 301 G fluid reservoir 1, upper, opened up for connector to 10mm
2 211 611 313 J fluid reservoir 2, lower
3 211 611 805 E tube, cut to lenght
4 211 611 833 D rubber gasket
5 selfmade connector tube 10x1x40
6 common rubber-o-ring 11x1
7 common tube clamp 12



Good luck

VeeDee


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