The Finish Line

Where I left off was three weeks ago and man has it been an interesting three weeks.  I have managed to get out in the garage at least one day each weekend (even during my weekend class I took) and fought to finish this project.  I was able to get rotors and calipers mounted on both sides and started installing the new master cylinder.  And that is pretty much when everything when down the crapper...

Drivers Side

Passenger Side

Bench Bleeding the New Master Cylinder

So I get the master cylinder bled, and mount it to the firewall.  I then go to connect the pushrod to the brake pedal and attach the brake switch to the pushrod and pedal as shown in the diagram below...

This is What it Looks Like When Things Go Right

I get everything together and decide to check if it works.  I connect the battery and now my brake lights are on all the time!  What the hell happened???  So I start scouring the web for ideas and it looks like there might be something wrong with my switch.  I then decide to clean the switch, maybe it is stuck always contacting the connection.  I get play back in the switch and check it when it is not hooked up.  The brake lights are off and they come on when I add pressure to the switch.  Well that's good, the switch doesn't seem broken.  So I hook the whole assembly back together, reconnect the battery, and the damn lights are still always on!  Son of a....

I disassemble the who contraption thinking that there is something wrong with the new pushrod.  Keep in mind, every time I  install or disassemble this contraption requires me to wedge my fat ass upside down between a seat and huge steering wheel, all while working in an area that my fingers can barely reach with the steering column and all the pedals.  It is a real pain and uncomfortable.  So I get the new pushrod out and decide to compare it to the old one.  There is probably 1/8" more steel at the end of the new pushrod than the old, so I decide to grind some of the end of the new one down a bit.  After grinding, refitting, seeing the lights still on, swearing, disassembling, and grinding some more about 3-4 more times, the length is the same size as the old pushrod I pulled out.  I install the new pushrod one last time, connect the battery, and not the lights aren't only not on, but now they don't even work at all.  You have got to be kidding me!!!!  Now I go to the message boards and start begging for help.  You have got to be kidding me.  After trying a couple more different things (like adding plastic weld to build the tip of the pushrod) and spending 6 hours working on this, I decide to pack it in for the weekend and just order a new switch.

The new switch comes in during the week, and then I spend some more time on the project on Saturday.  I wire in the new switch, test it out (it works), and then use it in the assembly with the new pushrod.  An low and behold, it friggin works!  It is a miracle.  Feeling re-energized, I start to tackle mounting new brake lines to the new master cylinder.  I picked up a double flare brake kit and start to work on installing brake lines.

It's not perfect, but it works

I wish I could say this went smoothly, but I would be lying as well.  Actually come to think of it, nothing in this project went according to plan...the problem I was having with the brake lines was getting both fittings to thread at the same time.  I would get one side to thread, and then the other wouldn't.  I would back the line out, thread the other side in and then the original side wouldn't thread.  After lots of swearing and kicking things for a couple of hours, I finally got the brake lines threaded.  Next project was the proportioning valve....

The proportioning valve regulates the amount of pressure from the front discs and rear drum brakes.  Since this is something that was never on the car, I had to fabricate some new brake lines from the distribution block to the proportioning valve on the rear brake side.  The kit also came with a mount that connected to the master cylinder at the firewall.  Anything that could have went wrong mounting it pretty much did.  The bolts that connect the master cylinder, and now the bracket, to the firewall decided they wanted to stop threading.  Once I won that battle, the brake lines decided they didn't want to thread in the distribution block and proportioning valve at the same time.  It was an awesome time.  Something I will be sure to look back at fondly later in life (did you catch the sarcasm?  I laid it on there pretty think).

Master Cylinder with Proportioning Valve mounted.
The last brake line from the front of the Proportioning Valve (below Cylinder)
to the Distribution Block (far right of picture) was a royal pain in the ass. 

So I finally got all the brake lines connected and tightened everything up, but then something funny happened.  I disconnected the clutch pedal linkage to get access to the distribution block (you can see it disconnected in the lower right corner of the picture above).  And after I reconnected the clutch linkage assembly, I went and pushed to clutch and watched the pedal go straight to the floor and not come back.  Fantastic.  I basically had to crawl under the car and reconnect the linkage at the clutch fork.  I also decided to adjust the clutch linkage and now the clutch pedal feels a little bit firmer and responsive.

Marissa was even nice enough to stick around and help me bleed the brakes.  After addressing a few small leaks, the brakes were all bled and the pedal was firm.  I was finally starting to feel good about this project.  I cleaned up the tools in the garage and moved some of the old parts out of the way.  I then reconnected the battery and I looked at the back and see the damn brake lights on again!!!!  You have got to be kidding me!!!  This can't be happening.

So after I disconnect the battery and go wedge myself back between the steering wheel and seat again.  I try to remove the pushrod, but since the master cylinder is tightened to the firewall, I can't get it to budge.  Frustrated beyond belief, I call it a night.

And that finally brings me to tonight.  I have found throughout this project, that it kills me during the week that I don't have time to get out there and finish it, but when the weekend finally comes around I am ready to go.  So tonight I went out there, loosened the master cylinder from the firewall, and replaced the new pushrod with the shorter old pushrod.  I reassembled the brake pedal contraption, connected the battery, and the brake lights weren't on!  By this point, I was ecstatic when I would connect the battery and the lights wouldn't automatically be on.  So I try the brake pedal, and the lights never work.  Crap.  I go back out, disconnect the battery, remove the switch from the pedal, and bend the tabs in towards the pushrod.  For what is probably been the 20th time now, I reconnect everything back on the brake pedal and reconnect the battery.  Lights don't automatically come on, could this be the time?  Try the brake pedal, and holy crap, the lights work.  Victory!!!!

I still need to put the wheels on the car and get it out for a test drive.  I also need to get an alignment done, but for now, I am happy that I have made it this far.  And for the last and final touch from tonight, I put my new Hoonigan sticker on the rear window: