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Re: Aluminum master cylinder upgrade [Re: roadrunninMark] #3102541
12/15/22 12:04 PM
12/15/22 12:04 PM
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Sniper Offline
master
Sniper  Offline
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Originally Posted by roadrunninMark



**For manual brakes: bore that back of the piston on the 15/16",** Can someone explain exactly how to do this?


It means that the M/C piston does not have the retaining groove machined in it to use a manual brake pushrod.

I just used a 4 bolt 15/16th M/C.

Dorman M80266

Re: Aluminum master cylinder upgrade [Re: Sniper] #3102605
12/15/22 03:41 PM
12/15/22 03:41 PM
Joined: Sep 2003
Posts: 20,500
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moparx Offline
"Butt Crack Bob"
moparx  Offline
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Posts: 20,500
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Originally Posted by Sniper
Originally Posted by roadrunninMark



**For manual brakes: bore that back of the piston on the 15/16",** Can someone explain exactly how to do this?


It means that the M/C piston does not have the retaining groove machined in it to use a manual brake pushrod.

I just used a 4 bolt 15/16th M/C.

Dorman M80266




in order to modify the piston for the groove the rubber retaining ring needs, the master needs to be disassembled, and the rear piston chucked up in a late.
you then need to know what push rod you are going to use, so you can determine the distance from the rear edge of the piston the groove needs to be machined.
then using the proper width grooving tool that fits inside the rear piston bore, you can easily make the groove necessary for the rubber retaining ring to fit into.
lacking a late and the necessary tooling to machine a groove, [and most do not have access to this stuff as i do] you can obtain a piston with the necessary groove already there that fits your master, find a master that is the size you need with the necessary retaining groove already in the rear piston, or make a substantial stop that will prevent the brake pedal rod from pulling out of the master cylinder, allowing the rod to fall toward the floor, causing complete brake system failure and possible severe damage to you and your car if this happens at the wrong time.
beer

Re: Aluminum master cylinder upgrade [Re: moparx] #3102843
12/16/22 12:05 PM
12/16/22 12:05 PM
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Posts: 3,037
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roadrunninMark Offline
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Bob, I don’t have those tools. Do you think the piston from a 1 1/8” m/c will fit in a 15/16? If not, I will just have to get a unit from dr. Diff. I don’t want the pushrod to fall out.

Re: Aluminum master cylinder upgrade [Re: roadrunninMark] #3102869
12/16/22 12:54 PM
12/16/22 12:54 PM
Joined: Sep 2003
Posts: 20,500
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moparx Offline
"Butt Crack Bob"
moparx  Offline
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north of coder
the 1 1/8 piston is 0.187 [3/16"] too big to fit into a 15/16" [0.937] bore master cylinder.
that said, even if one were to machine the 1 1/8" piston to fit the 15/16" master, i'm "ass"uming there would not be any structural integrity left in the piston because the basic piece would have very thin sections left in spots, due to being machined for the bigger bore to begin with.
i'm just guessing about that, because i do not have an inch and an eighth piston to compare to the fifteen sixteenth piston.
just do the right thing and get the 15/16 unit from the good doctor like you mentioned. brakes are not where you want to compromise safety.
beer

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