my latest project 1962 COW-LOOK bug

[danny gabbard]

Doing some plumbing from resevoire to mastercylinder. Stainless tube i welded together for master. And I used a oval fluid tank or can and made a little alum tray to keep any drips off paint

[danny gabbard]

Mocked up, And now take it apart and clean and paint .

[Kaferdog]

I am impressed .....AGAIN...!!...

[low oval]

that's it!  i'm not doing anything else on my bug till you finish this car.  Or at least email me before you do these mods so I can see if I want to wait.
Nice job!

[vwcab]

that's it!  i'm not doing anything else on my bug till you finish this car.  Or at least email me before you do these mods so I can see if I want to wait.
Nice job!

X 2,so many neat tricks and modifications.

[61SNRF]

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Don't mean to be a spoiler, but you know this limits the function of having a dual circuit M/C, right?
Someone needs to make a stealth reservoir with two chambers and two feed hoses to provide fluid to each port. In case of catastophic failure of one circuit, there would still be a supply of fluid to the remaining circuit.
Otherwise, outstanding attention to detail and craftsmanship. Well done Danny.

[DKK - Lisa]

that's it!  i'm not doing anything else on my bug till you finish this car.  Or at least email me before you do these mods so I can see if I want to wait.
Nice job!

Anything else?  Have you been wrenching on the Oval? 

[roland]

[ Attachment: You are not allowed to view attachments ]
Don't mean to be a spoiler, but you know this limits the function of having a dual circuit M/C, right?
Someone needs to make a stealth reservoir with two chambers and two feed hoses to provide fluid to each port. In case of catastophic failure of one circuit, there would still be a supply of fluid to the remaining circuit.
Otherwise, outstanding attention to detail and craftsmanship. Well done Danny.

Something like that? : (not my work btw, but good stuff!)

Right, I finally done something thats worth posting up! 

The first part of this was siamising two brake fluid resevoirs together, as the car will be duel circuit, and I didn't want to fit a later plastic reservoiur.



I was actually really pleased with how this looked. 

Next up was to cut the wheel well to accept it, and adjust the pressing. I was really nervous about doing as if I messsed it up their was no going back! 

Anyway here's how it turned out! I think i'm happy with it! 





















Anyway, just thought I'd give you a bit more of a update!

Dude 

And nice work Danny, as always!

[danny gabbard]

[ Attachment: You are not allowed to view attachments ]
Don't mean to be a spoiler, but you know this limits the function of having a dual circuit M/C, right?
Someone needs to make a stealth reservoir with two chambers and two feed hoses to provide fluid to each port. In case of catastophic failure of one circuit, there would still be a supply of fluid to the remaining circuit.
Otherwise, outstanding attention to detail and craftsmanship. Well done Danny.

Thanks for your input and I see what your talking about, But I dont see this part failing and starveing any fluid. If I'm correct duel circuit meaning theres a plunger for each front and rear brakes that fluid is being pushed. instead of one plunger for both front and rear,Thats what should be of concern in brake fluid being lost.

[61SNRF]

The system is a failsafe in the event of some extreme failures and will probably never be tested in real life, so it's splitting hairs anyway .
The idea behind the extra capacity of a separete reservoir is to ensure there is a adequate supply of fluid for the remaining good circuit. In your design, if there is a failure of one circuit there is little fluid in reserve for the remaining circuit.
I think a small improvement would be to put the Y right behind the reservoir so that you at least had the pipes and hoses to retain a small supply of fluid for each circuit indepenant of the other.

[gibber!]

Thanks for your input and I see what your talking about, But I dont see this part failing and starveing any fluid. If I'm correct duel circuit meaning theres a plunger for each front and rear brakes that fluid is being pushed. instead of one plunger for both front and rear,Thats what should be of concern in brake fluid being lost.

I suppose you're right.
As long as there is only a failure in one of the circuits i.e. front or rear, then the other should retain the fluid already in the brake lines and still function.
Normally dual circuits are basically two independent systems with two reservoirs just contained together.

[61SNRF]

A long standing design philosophy is Form follows Function. If you're going to change or modify any system then it should perform as good or better than the system it replaces.
Then make it look purdy .

[Rick Meredith]

The system is a failsafe in the event of some extreme failures and will probably never be tested in real life, so it's splitting hairs anyway .
The idea behind the extra capacity of a separete reservoir is to ensure there is a adequate supply of fluid for the remaining good circuit. In your design, if there is a failure of one circuit there is little fluid in reserve for the remaining circuit.
I think a small improvement would be to put the Y right behind the reservoir so that you at least had the pipes and hoses to retain a small supply of fluid for each circuit indepenant of the other.

I think on the '67s they had a common reservoir with a little "dam" in it to separate the circuits. They could share the fluid up to the level of the dam.

[danny gabbard]

I just made due with what I had. This deal is very low risk , you could probably cork the end of tube and drive it a hundred thousand miles and never have a problem. And if everybody followed the form and function rule you would not see 145s in the front of a lowered vw . Sorry if I sound like I am ranting.

[61SNRF]

No, you're right. I knew someone would say something so I threw it out there.
It might have something to do with the original Federal Safety requirements that there was a complete separate system for each circuit. In actuality, I see little need for a large reserve of fluid in a drum brake car. Disc brake cars may require a little more reserve due to pad wear displacing the fluid.
What I would like to see is an early reservoir split apart and a divider inserted down the middle with two outlets on the bottom. This would be a stealth way to hide the dual reservoirs.
Running 145's is a little different than adapting a late model brake system to an early car too. I still believe in the three F's.

[danny gabbard]

Trying to get some loose ends like plumbing and electrical sorted out. I ended up with a faucet fuel pump and made a bracket to rubber mount. Painted and ready for install. And a bosch swith to turn on and off, Just want to thank paul or (plastic back) for switch !! God I hope this is DOT approved !!!!

[danny gabbard]

Few more shots of painted and installed. And will use braided line from pump to stainless bulk head fittings in tunnel of pan.

[danny gabbard]

Few things in trunk that I finished. 1st is a little plate to locate spare from slideing around and rubbing paint. and the finished brake fluid reservoir finished and painted and mounted.

[danny gabbard]

And the alum knob I am going to use to make key for hella battery cut-off swith to look like heater knob.

[58vw]

that is trick....very cool idea...awesome work

[Chris W]

Great work as always!! I like the way you did the brake line through the tunnel to the passenger side.

[TexasTom]

DG,

Awesome work on the details!
That fuel pump mount is the TITS! ... super clean. And, the stock switch is the only thing to use ... back when I built my '67 race car I used lighted knobs (like emergency/defroster(green means GO!) flasher) so I'd know when everything was on; one for the ignition and one for fuel ... worked GREAT.
Also love the knob for the main cutoff ... just SUPER clean, as always.
TxT

you can barely see the green lensed knobs ...π

[TexasTom]

By the way, what tool and/or process do you use to roll the edge over on the fuel pump mounting bracket?

[danny gabbard]

Thanks tom and chris, Tom the process is called hammer forming. You make a pattern and transfer and cut out to blocks of alum the shape of part to be, Can also be made of hardwood ! I usually only use hard wood on soft materials like alum , brass , copper. So now blocks are cut and holes drilled for bolting blocks together, Same holes in this case that pump will mount to. Now add a peice of material that part is going to be made into and scribe around blocks with dividers to get the sides or material to be hammerd down, and go make parts. DO NOT try and hammer complete in one hit, Go around several times turning edge very slow, So material dos not ball up. Again thanks Tom, Or brother of JACK ! That shot glass is working out fine!

[speedwell]

any updates dany

[danny gabbard]

Hi fabs, Here is a little work I have been doing on the running boards. First pictures are of the untouched new running boards that to me dont fit that well !

[danny gabbard]

Well as we can all see, They are a bit short on the ends!!! So first thing is to make a pattern of what there suppose be. So I made alum ends and trimed them to fit, Later I will overlay them on added areas welded to running boards. And trim and turn a new 90 degree flange on all the ends.

[danny gabbard]

Now I will cut the ends off and weld filler strip on the ends. And a sample before and after.

[danny gabbard]

Now for the finished parts fit to car.

[danny gabbard]

Couple close ups of front fenders and of before and after rear corners