OK - Let's see - started this brake restoration project sometime around July and last checked in with y'all in January. As you can see, things don't move to fast for me. But just to catch up, let's start at the end. As of yesterday:
- Parking brakes rebuilt (except for actuators which, A - can't come out without pulling a lot more stuff than I wanted to, B - are about 1/8" steel and just ain't going to rust out before the frame does)
- Rotors were fine as they were with a little surface sanding (all run outs in spec)
- Calipers remounted. The are two free warranty replacements from Corvette America on the front (yep they honored the lifetime sleeve corrosion warranty after 20+ years) and rears rebuilt by me - previously SS sleeved)
- New master cylinder (cheaper than sleeving the original - anyone want an original 1980 master cylinder - just kidding).
- Fluid filled and bled yesterday - one small leak on a bleed valve which I'm working to correct.
So why so long to get here. Most of it was the lines per my earlier posts. None of the them matched the originals with the biggest problems being the lines from the master cylinder (see earlier posts). Nevertheless, had most mounted but finally gave up on them when the rear caliper lines simply were not bent correctly to fit into the tight areas threading around the caliper and after several bending tweaks to get the rear crossover line to fit it was beyond salvageable.
So on recommendation from others I contacted Classic Tube to see what they had for the master cylinder lines. I figured if they matched the originals maybe most else would be correct. They told me that what was on the pictures online were what they had. But per earlier posts, those are not correct I don't know why so many places sell those as the replacements. They will not fit a C3 with cruise control. Anyway, they recommended that I send them all the originals and they'd bend up a custom set.
So there I was packing up the originals when a funny thing happened on the way to putting the original lines into the box which my "new" lines from Dr. Rebuild had come in back in 2011. I noticed the name on the box was, ta da, Classic Tube. So I dropped a note off to my contact at Classic Tube noting that the lines which were not fitting correctly anywhere in my car were originally from them. Now, given the time since purchase and not having purchased directly from them I was not expecting a free replacement set. But I asked if as a favor they could work with me on the cost of replacements. They offered a set for $50 +shipping. Good deal. So I sent off all my original 1980 lines (except for the right rear caliper line which disappeared in a clean up apparently). My instructions were:
1 - Replacement set in plain steel. Plain steel had gone 24 years of driving without a failure and, given the hassle of making even minor corrective bends on stainless, I figured if I got 24 years out of a new steel set that would take me to age 81 - good enough.
2 - Make the front to rear line in two pieces. You know the front to rear line - all in one shot it runs along the frame, THROUGH the center cross member, turns 90 deg. left at the rear cross member, then 4 inches later goes 90 deg. vertical to the top of the rear cross member, then does a 60 deg down to go over the top of the rear cross member to precisely (within 3 inches
) line up with the rear line splitter block. My directions were to replicate the original single line with a 2 piece line. The union would be a few inches behind the center cross member . That way you can do all the gyrations required to thread the rear section up over the cross member without half the line being trapped and essentially immobilized on the other side of the center cross member. Note, getting the single piece line in can be done, as I was able to to this. But it will never be flush with the framing again and takes hours to do at the costs of millions of lives. It's almost as bad as rebuilding the parking brakes - but that's another story.
3 - Create the right rear caliper line as a mirror image of the left, which I still had.
Three weeks later the custom lines arrived. The good news, they matched much better than the set I received in 2011. The bad news.
1 - They were made in stainless steel not plain steel as I requested. OK, not the end of the world and technically an upgrade. And given the much improved fit this was far less of an issue. Still, the minor tweaking needed to get final alignment of the line nuts and receptacles was still somewhat challenging.
2 - The replacement front to back line came in one piece instead of two as I requested.
3 - There was no right rear caliper line.
So after an email and agreement from Classic Tube, the replacement front to rear line went back with markings as to where to cut it, add line nuts, and flare it for a union. And the original left rear caliper line went back to be a guide for making a replacement for the missing right rear caliper line.
A few weeks later these parts arrived.
Despite the problems noted with missed instructions on the first replacement set Classic Tube sent to me, I have to give them high marks for working with me on such an unusual request and for the accuracy of their custom made set based on the originals I sent.
So this leaves me now with reinstalling the radiator, fan, hoses, shroud, etc. and finally attempting an engine start for the first time in 6 years with some reasonable expectation that I will be able to stop the car if it actually starts. Tune in next year folks - OK, maybe July. I have some business travel interfering with my home projects. As my big brother put is so well many years ago, "If it weren't for work I'd be able to get a lot done around here".