There have been a couple of articles previously published in TTT 2 showing very nicely how this can be done so it is not really new ground. The author is not trying to re-invent the wheel but thought that some owners would welcome something like this in a high quality kit form.
The workshop manual (WSM) stipulates that the brake fluid level should be checked and replenished every 1000miles/1600km. Access to the filler cap on the M/C is not user friendly due to the M/C mounting arrangement which entails crawling into the body tub. Not everybody has the ideal figure to want to do this on a regular basis. A remote brake fluid reservoir is a sensible worthwhile modification which allows daily inspection of the car’s brake fluid level simply by raising the side of the bonnet (hood).
The brake reservoir kit does not connect into the actual hydraulic lines; it connects into the integrated master cylinder (M/C) reservoir through the blanking plug at the rear. This reservoir then feeds the hydraulic lines.
The remote reservoir is essentially an extension of the volume of fluid available for the hydraulics and has nothing to do with the actual braking system as such. This will obviously work only on master cylinders which are factory fitted with a 1” blanking plug at the rear of the cylinder (as are all replacement Lockheed style cylinders on the market e.g. MOSS Part#180-730). The filler cap 1 1/4” has to be replaced with the non-vented type and non-vented caps are available or the vent in the existing cap can be blocked off. *The master cylinder in Fig 1 is not part of the kit but for illustration purposes only. Check to see if your M/C has a rear blanking plug before ordering this kit.
Fig 1- Basic Kit contents*
An 8mm rubber cushioned P-clip is included in the kit to fix the flexible dash 4 braided stainless braided Teflon hose to the bolt on the pedal box side cover. The mount for the battery clamp hook J-bolt is also included. It may be require to add a bracket to the clamp hook if the threads are not long enough to fit the reservoir mount supplied.
Fig 2 – Connection to master cylinder.
Fig 3 – Reservoir mounted on battery bar clamp hook (J bolt).
The kit may be installed without removing the master cylinder completely. It will be necessary to drain off some brake fluid to below the level of the blanking plug. The better option is to remove the M/C and replace the fluid as it is hydroscopic and should be changed at two yearly intervals as a matter of course.
There is not much clearance between the blanking plug banjo bolt and the cross member and it is advisable to remove the two M/C securing bolt and tilt the M/C to fit the banjo.
The blanking plug provided is a re-furbished second hand part which is tapped in the lathe to suit the banjo bolt and is supplied with a new 26x31x2mm copper sealing washer. If you want to retain your original blanking plug and tap it yourself feel free to do so but it must be done accurately to prevent sealing problems. This is not a job for hand drilling. I can offer an exchange service if required.
The reservoir should be mounted on the same side of the car as the M/C which differs from LHD to RHD. After installation, re-check for leaks at regular intervals.
In case of any problems please contact me at the address below.
Liedberger Weg 6A
Tel +49 211 371529 after 5pm.
Email : email@example.com
Note: declan underscore burns at web dot de
Ed’s note: Declan has drawn up a draft catalogue of his modifications which readers may have via email if they wish to contact him. He updates this every now and again when he has better photos or comes up with new ideas. Details of most of the items have already appeared in TTT 2, but there are a couple still to appear and they will be included in the June issue.