Clutch master cylinder overhaul #3

I was still struggling with the sticking piston of the clutch master cylinder.

I thought I should give up and look for the new part for the replacement. And to for my curiosity, I started to destroy and disassemble the clutch master cylinder piston by drilling.

When I was drilling the piston halfway, I didn’t have any specific idea, however, I thought to tap the piston to make the thread. I started to turn the tap handle, and I felt the feeling that the piston was moved. So, I tried to pull it, and then suddenly the piston was removed from the cylinder.

Finally I could extract the rusty piston!

I observed the extracted piston. It looked there was no risk of the leakage of the fluid because the hole I made in the piston was not penetrated. Thinking the function that this part only holding the rod connected with the clutch pedal, it could be reused if the hole would be filled by the hard material.

However, before repairing the holed piston, I started to restore the cylinder because repairing the piston would not make sense in case the cylinder could not be reusable.

The honing tool I used for the brake master cylinder was too big for the clutch master cylinder so that I acquired the smaller diameter honing brush.

After honing the inside of the cylinder, it looked not bad and reusable.

As same as the brake master cylinder, after honing and polishing the parts became fine even though they were rusty.

Because I could confirm that the cylinder could be reused, I tried to fill the hole in the piston with solder.

Heat the piston by a burner.

And fill the hole with solder.

And grinded the solder with a sand paper to make the piston head flat.

The result became like this.

(My original blog was written on 17th July 2009)

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