Leaky master cylinder idea


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Posted by David Sherman on Monday, January 23, 2006 at 5:34PM :

J-Gilly's question below reminded me of something I was wondering if anybody tried. I have two trucks with pitted master cylinders that I overhauled myself. I honed them both very thoroughly with the hone mounted in the drill press, using brake fluid as a lubricant to keep the stones clean. Nevertheless, I couldn't hone all the pits out, which causes some slight leakage.

My question is this: has anybody tried simply boring out the MC just enough to get rid of all the pits. I don't have a milling machine, but have a lathe and could probably make some sort of mounting jig to hold it on the lathe. I could also borrow the use of a milling machine. It seems to be the fixturing alignment wouldn't be critical since the bore doesn't have to align with the pedal very accurately and there's nothing else that has to align with it at all. One would only have to take off a few thousandths to get past all the pitting. After boring, honing should be able to remove all the tool marks. I know that a sleeve is a better fix, but it seems to me the rubber cup should be able to expand enough to seal in a bore that's only .010 or so oversized. It even occurs to me that some of the "rebuilt" MCs on the market might have been bored out oversized. Anybody tried this or have any reason why it shouldn't work?



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