The day my "onboro ALFA" would revive

I disassembled the brake master cylinder again I repaired on the other day because the behavior of the piston seemed to be not smooth enough.  When I removed the piston at the last time , I checked the condition of the rubber and it looked good.  Therefore , I reassembled it without replacing the rubber. However , again I disassembled the brake master cylinder ’ s piston and checked its condition carefully in order to reassure myself. I disassembled and cleaned the piston and the spring. The condition of the original rubber was not bad , but I replaced it once with the rubber part of the repair kit. Again , however , I felt that the quality of the rubber parts of the repair kit ( left one ) seemed to be poor…. I also assembled the piston into the cylinder as a trial , however , the tight contacting feeling was not enough. As my conclusion , I judged the condition of the original rubber parts were good enough and decided ...

I cleaned the inside of the master cylinder again using the honing machine. http://onboroalfa.blogspot.com/2018/10/clutch-slave-cylinder-honing.html ? m=1 I removed the rust from the spacers , nuts and washers which were used for fixing the brake master cylinder on the body , and painted the brake master cylinder , the linkage rod and other small parts. I did the “ home made baking finish painting ” with the electric heater. Apply the brake fluid on the piston and insert it to the cylinder. Assemble the piston push rod , which to be connected to the linkage rod , in the order of ( 1 ) ~ ( 6 ) . #1 rod to be inserted to #2 washer , and it to be fixed in the groove inside the cylinder with the circlip . And set the #4 plate on it , insert the #5 spring and fix the spring with #6 nut. These would be covered by the rubber boots.  It was not completed yet , but the work of this day was ended. ( My orig...

I cleaned the disassembled brake master cylinder gradually in my spare time. Cleaning of the master cylinder piston Before: After: It was not dramatically cleaned…I had to make effort a little more! I also cleaned the master cylinder with a wire brush. The inside was also cleaned.  It seemed that this could be reused. ☺︎ It would take a while to start this type of work , but once it is started , it's fun to do such work while listening to the radio at night. ( My original blog was written on 10th Jun 2009 )

I started the overhaul of the brake master cylinder after the clutch slave cylinder. This day ’ s work was removal and disassembly of the brake master cylinder. My “ onboro ALFA ” is early type ( Mk. I ) 1750GTV RHD.  The brake master cylinder is made by BONARDI and it is installed on the frame under the floor together with the clutch master cylinder ( this is made by BENDITALIA ) . Regarding the removal , there was a little try and error. ( 1 ) Remove the pipes Then , I tried to separate the linkage rod connecting to the brake pedal.  However , the fixing nut was so hard that I changed the process. ( 2 ) Remove the bolts fixing the brake master cylinder on the frame. ( These bolts were also fixing the clutch master cylinder penetrating the frame. ) ( 3 ) & ( 4 ) Separate the linkage rod from the brake pedal , and remove the brake master cylinder together with the linkage rod. ( The linkage rod and the pedal were fixed by a split pin. ) ...

It was raining from morning on this day. It was not bad for me because I could spend time in my garage without hesitation while my wife and kids were watching TV in the house.  I fixed several repairs that I had thought I should do. To replace the ignition coil with the blue coil again. The ignition system with the semi-transistor and the blue coil looked like a retro combination. I changed the routing of the wire harness for the fuel tank to prevent the wire harness being damaged by objects in trunk. Previously overhauled rear brake calipers were assembled to the renewed rear axle. I found the spring washers of the caliper fixing bolts were deteriorated , so I replaced them with new washers. Rear axle and brake would be like a new if the rotor would be nicer. When I worked at the engine room of my car , there were some dark areas depending on the repairing part.   To improve this I tried a small idea for the li...

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....

I could find the time on Sunday and started the installation of the overhauled brakes. First of all I installed the new brake pads.  I bought them with 6 , 000JPY for a set of front and rear when shop did the sale.  I thought it quite reasonable. Nice! In the next I replaced the brake hoses with the stainless-mesh lines 15mm flare nut wrench was necessary to remove the hoses but I couldn ’ t find it ( I think 15mm is not popular size ) .  So , I found a set of crow foot wrench at a tool shop and bought it. I could loosen the nut only little by little.  But it seemed useful in combination with the extension bar to turn the nut if it located at complicated position. Overhauled caliper and new stain mesh brake lines were installed. The stainless mesh brake lines were not showier than I thought. Now the caliper and brake hose looked fine.  But other parts were not beautiful!  I should grind the surface of ...

I removed the rust from pad springs and pins , and painted with the Zinc-rich paint. I used a spray paint.  Because the pad springs and pins were small parts , I heated them using the oven toaster in my kitchen for baking finish this time. I didn't say it to my wife because she would say definitely “ No ” if I would ask her to use the oven toaster. ☺︎ The finish of the pad springs and pins became nice.  I was very satisfied with the results.  However , those would become dirty soon by the brake pad dust…. (My original blog was written on 12th May 2008 )

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 )