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)

Comments

Tip to repair rubber parts

I disassembled the rear axle before. There had been no progress on it because I started the repair of the fuel tank during my summer holiday. While painting the fuel tank , I repaired the torn rubber boot of the parking brake wire. I guessed it didn ’ t cost high because it was small rubber part. But I wanted to try the repair method I read on the magazine article before. This was the condition before the repair. The rubber was torn apart and separated almost. I used this self-adhesive type butyl tape. I pasted lots of small pieces of the butyl tape on the back side of the rubber boot. As time goes by , these tapes would melt and stick together. After this I applied plenty of adhesive “ Super X Black ” on the rubber boot. On the magazine of MOTO MAINTENANCE , I read the article that the motorcycle seat was repaired with this method. So , I wanted to try it. After drying 1 day , it became like this....

Pad spring repair

One of the springs to hold the brake pads was broken. At first I thought to buy it, however, I tried to fix it using rivets. It seemed to be strong enough just to hold pads. Later I removed the rust and cleaned them. Note: I have been using this repaired pad soring for 10 years and there is no issue. Pad spring is not an expensive part ptobably (I don't know the exact price), but it is easy to repair if you have ar1750gtv hand rivetter. (My original blog was written on 10th May 2008 )

Body repair around the fuel tank

I found some rust at the flange in body around the fuel tank as I expected. I believed this level of rust in this area was quite usual for old Alfa Romeo. It seemed that this area didn ’ t influence on the body strength , however , I was considering the method what I could do by myself. Anyway in order to prepare the sheet metal for the repair at first , I started to look for the store where I could buy some sheet metal near my house. I tried to research the store on internet , but I couldn ’ t find appropriate stores. Finally I asked the person at repair shop , who did maintenance of my Renault 5 , about the store I could buy some sheet metal. They kindly taught me the store , but at the same time they gave me some sheet metal for free. That was enough volume for what I wanted to do. I didn ’ t expect it. Thanks a lot!!! (My original blog was written on 12th Sep. 2008 )

The day my "onboro ALFA" would revive

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