JP Posted September 16, 2023 Share Posted September 16, 2023 I've been rebuilding the front brake hoses today and I've come across 2 issues. It an imperial 1999 chassis with widetrack suspension and std brake calipers.1. Regarding the fitting of the caliper banjo bolts, the Assembly guide refers to a thick and thin copper washer that is fitted either side of the banjo. I need to order these, but the Caterham parts site only refers to one washer which, it says is fitted either side - here. Have things moved on and I just need two if these - one either side of the banjo on the bolt? Or are there part numbers for the thick and thin washers that I haven't been able to find? There is nothing in my De Dion parts manual.2. At the inboard end of the hose, I am finding that the brake pipe nut on the rigid pipe is hitting / fouling on the flexi pipe nut before the rigid pipe nut is properly snugged down. It's as if there isn't enough thread left on the flexi hose once I add the washer either side of the ally skin and the shakeproof washer and then the hose securing nut. I've compared against my original hoses and they look the same so I'm not sure why this is happening, unless either (a) it was fouling before and I didn't notice (i didn't build the car) or (b) I'm, using thicker washers either side of the skin...Can anyone help with either issue please? Link to comment Share on other sites More sharing options...
Wrightpayne Posted September 16, 2023 Share Posted September 16, 2023 Re 1 - I sized the old washers (I only had 1 thickness) and ordered new ones from ebay. Inner diameter, outer diameter and thickness - they were a few pounds (<5) for 20.Ian Link to comment Share on other sites More sharing options...
JP Posted September 16, 2023 Author Share Posted September 16, 2023 Thank you. I do have 1 copper washer so can look at that... Link to comment Share on other sites More sharing options...
jbcollier Posted September 16, 2023 Share Posted September 16, 2023 1: a copper washer either side ande you're good. Any auto parts store/industrial supply should have them.2: I don't think you need the two large washers as the brake line itself helps hold that end of the flex hose steady. Link to comment Share on other sites More sharing options...
JP Posted September 17, 2023 Author Share Posted September 17, 2023 Thank you #4 -so at the inboard end, just pass the hose through the skin and secure on the inside with the shake proof washer and hose nut? Link to comment Share on other sites More sharing options...
jbcollier Posted September 17, 2023 Share Posted September 17, 2023 Can you post photos of the hose end, washers, etc. Just want to make sure there nothing else amiss first. Link to comment Share on other sites More sharing options...
jbcollier Posted September 17, 2023 Share Posted September 17, 2023 Can you post photos of the hose end, washers, etc. Just want to make sure there nothing else amiss first. Link to comment Share on other sites More sharing options...
John Vine Posted September 17, 2023 Share Posted September 17, 2023 JP, you may already have this info, but the Assembly Guide for my old 1999 1.8K says:JV Link to comment Share on other sites More sharing options...
JP Posted September 17, 2023 Author Share Posted September 17, 2023 Thanks JV. That is exactly as per my printed Assembly guide. The same is in the slightly later electronic one. I'll go and take some pics... Link to comment Share on other sites More sharing options...
JP Posted September 17, 2023 Author Share Posted September 17, 2023 Here are some pics of the inboard end: Link to comment Share on other sites More sharing options...
jbcollier Posted September 17, 2023 Share Posted September 17, 2023 Tough to say for sure from one photo but your jam nut looks too thick. Should be more like this: Link to comment Share on other sites More sharing options...
JP Posted September 17, 2023 Author Share Posted September 17, 2023 I think you might be right. That is what I am used on brake hoses, but those are the nuts that come with the goodrich hoses. I'll order some anyway and experiment. Would you happen to know the spec of the lock nut I need?Looking back, there was an error when I ordered the hoses and got a set for uprated calipers sent to me instead by mistake. The fronts were then replaced with the correct hoses for std calipers, but I don't think I got the additional fixings. I think I need the fixings that should come with this hose. Link to comment Share on other sites More sharing options...
JP Posted September 23, 2023 Author Share Posted September 23, 2023 Quick update:Banjo end - the 7/16 copper goes above the banjo, where there is a shoulder on the bolt profile. The 3/8 washer goes between banjo and caliper - thanks Redline!Inboard end - clearance issue fixed with the correct hose locknuts - thanks again Redline.Now I've bled the system, it looks like I need a new master cylinder. I was expecting that anyway really, given how long the car has been off the road. Just looked at the parts site - they've gone up a lot in price since I last bought one! £420 for the AP racing one! I prefer the pedal feel of the AP, but at £420 I might go back to standard for "only" £260...Anyone know of any cheaper sources or a generic AP part number for the m/cylinder so I can look elsewhere?Looking further I have a vague recollection that the Caterham AP Racing one was a 6093, which AP say is obsolete and replaced by the 9093. Does anyone know if this, from Demon Tweeks might be the replacement suitable for the 7? Link to comment Share on other sites More sharing options...
Member Jonathan Kay Posted September 24, 2023 Member Share Posted September 24, 2023 How about refurbishing rather than replacing the master cylinder? DIY kits are available for many AP cylinders. And Bigg Red have an excellent reputation.Jonathan Link to comment Share on other sites More sharing options...
JP Posted September 24, 2023 Author Share Posted September 24, 2023 Thanks - I'll speak to Bigg Red - they did my calipers and I was very impressed. I've tried refurbing a MC before and I gave up trying to get the old seals out... Link to comment Share on other sites More sharing options...
Iamscotticus Posted September 24, 2023 Share Posted September 24, 2023 For years, 80s-90's, the standard MC was the Girling 74660152 used on the Triumph Spitfire 1500, but with a reservoir for horizontal mounting. I have recently purchased the direct descendant, TRW GMC226, or TRW PMC 146, which I have found to be a direct replacement. I purchased mine from the David Manners Group. I will have to replace the push rod with a threaded type, these are available.A friend of mine says he can get the MC with the correct reservoir from Powertrack brakes https://www.powertrackbrakes.co.uk/Buying new manufacture is usually the better option than rebuilding Link to comment Share on other sites More sharing options...
JP Posted September 24, 2023 Author Share Posted September 24, 2023 #16 - thank you. I agree about buying new, providing it is a reputable manufacturer. I'll look into those 2 links. Thanks again. Link to comment Share on other sites More sharing options...
JP Posted September 25, 2023 Author Share Posted September 25, 2023 So I've been told today by more than one source that both std and uprated MCs are both supplied by AP and that the only source is Caterham or Redline. Redline has my money. Link to comment Share on other sites More sharing options...
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