The weight saving thread

[Chris W]

Bus reservoir has to be lighter than the stock set up.



Finished brake parts-

[Wünderwolff]

So much paint, it must make the parts make weigh in heavier than before the drilling 

This really is my favourite thread ever! Don't stop the drilling!

[Pas]

Bus reservoir has to be lighter than the stock set up.

I agree, all we need to do now is to find a suitable alloy single circuit master cylinder, that has to be even lighter

[Neil Davies]

Bus reservoir has to be lighter than the stock set up.

I agree, all we need to do now is to find a suitable alloy single circuit master cylinder, that has to be even lighter

Having had partial brake failure on a dual circuit street car, I'd much rather run a dual circuit m/c and forgoe the third helping of Cristmas pud!

Has anyone thought of the weight of the wiring on the cars? I was reading Andy Frost's Red Victor 3 (street-legal Pro Mod!) build up, and he said about using aircraft wiring as it's much lighter than automotive?

http://www.rodsnsods.co.uk/forum/garage/redvictor3-started-last-5064

Have a look through - it's awesome!

[Lee.C]

just remember

i dint weigh the weight, but sometime last year i changed out the original SC master cylinder on my 66.

i wanted to try something different so i fitted an aluminium master cylinder from a late model Nissan 4 cylinder car.

it was designed to work with a booster, but i just took it, redreilled the holes to follow the the holes inour VWs .

it sure is a lot lighter but i am not sure what the bore size is.

seems to be working OK so far.



main reason wasnt even for weight, i wanted the reservoir to be ontop of the MC and the ATE late model DC costs USD140 in my area, the Nissan MC can be found in near mint condition for USD20, so i decided to try it out and if it doesnt work, just swap back a VW unit. so far no issues yet.

Looks like its leaking abit 

Thats alot of effort dude - you could have just used a standard dual circuit master and a VOLVO reservior 

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=220707020027&viewitem=&sspagename=STRK%3AMEWAX%3AIT

[pupjoint]

nope, it has been a year now so far it hasn't leaked a drop. the ones u see are not leaks, forgot what they were.

the nissan MC came with the reservoir installed, aluminium and way lighter, plus they are everywhere in this part of the world.

not much extra work, just redrill and retap the mounting holes.

[Pas]

Bus reservoir has to be lighter than the stock set up.

I agree, all we need to do now is to find a suitable alloy single circuit master cylinder, that has to be even lighter

Having had partial brake failure on a dual circuit street car, I'd much rather run a dual circuit m/c and forgoe the third helping of Cristmas pud!

Has anyone thought of the weight of the wiring on the cars? I was reading Andy Frost's Red Victor 3 (street-legal Pro Mod!) build up, and he said about using aircraft wiring as it's much lighter than automotive?

http://www.rodsnsods.co.uk/forum/garage/redvictor3-started-last-5064

Have a look through - it's awesome!

Now I like single circuit iron m/c's and I like dual circuit alloy m/c's, but which is best? There's only one way to find out.........get the scales out 

Not sure if it's the same stuff Neil but thinwall wire is supposed to be a lighter alternative to regular auto wiring, price isn't too bad either. http://cgi.ebay.co.uk/Automotive-cable-wire-1mm-32-0-2-16a-thinwall-/220598569082?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item335cb3087a

[benssp]

Vehicle wiring products have thin wall cable, Bernie used it in the new loom

http://www.vehicle-wiring-products.eu/VWP-onlinestore/cable/thinwall.php

[Bruce]

I don't see much weight savings by reducing the insulation a tiny bit.  Notice how they make no claims of how much weight is removed?

Anyone found a source for aluminum wire?  That will weigh significantly less.

[paul_f]

I don't see much weight savings by reducing the insulation a tiny bit.  Notice how they make no claims of how much weight is removed?

Anyone found a source for aluminum wire?  That will weigh significantly less.

The weight saving comes from being able to using smaller size wire as the insulation can cope with it without breaking down.   From the ratings on VWP website, the 1mm2 standard cable can cope with 8amps but the 0.5mm2 thinwall can cope with 11amps.

[Chris W]

Every little bit counts right 

[Bruce]

That's right Chris.
did you drill out the e-brake pivot pin yet?

Now guess which one weighs 24g, and which one weighs 8g?

[Chris W]

Is one a repop?

[Bruce]

Is one a repop?

You could say that.  Yesterday I "repop'd" them from aluminium.

[Peter Shattock]

Nice drop of madness you have going on there Bruce!

Great quality work as ever too.

I don't have much of interest to contribute at the moment, but its good to see this threat is alive and kicking.

Peter

Is one a repop?

You could say that.  Yesterday I "repop'd" them from aluminium.

[TexasTom]

Is one a repop?

You could say that.  Yesterday I "repop'd" them from aluminium.

Those are super nice Bruce ... you gonna make more to sell?
Tom

[Bruce]

Depends on how much gets thrown at me.

[TexasTom]

Is this enough?
[ Attachment: You are not allowed to view attachments ]

[Chris W]

Very nice work Bruce!

Think they are lighter than the billet ones out there? They sure look nicer.

[Bruce]

I'm sure they are lighter.  Mine are 2mm thick everywhere.  Just like stock.  The billet type ones are thicker.
I didn't make them to be lighter than the billet ones. I just don't like any of the billet stuff you can buy.

[Fasterbrit]

Hi Bruce. Nice brackets! Out of interest, how did you press the swages into them? Very trick, did you make some kind of former? Regards, Matt

[Bruce]

, did you make some kind of former?

VW did.
After I cut out the Al from 2mm sheet and made the two bends, I put a stock steel bracket on each side, then squished them together.  It's not ideal because there's no allowance for the thickness of the material, but it does kinda work.

[Fasterbrit]

Ah... Good thinking Bruce. I like your style 

[Pas]

Anyone found a source for aluminum wire?  That will weigh significantly less.

How about this stuff.

http://delphi.com/news/featureStories/fs_2009_10_23_001/

Not sure how you get your hands on it though.

[danny gabbard]

, did you make some kind of former?

VW did.
After I cut out the Al from 2mm sheet and made the two bends, I put a stock steel bracket on each side, then squished them together.  It's not ideal because there's no allowance for the thickness of the material, but it does kinda work.

Very cleaver!!

[Bruce]

, did you make some kind of former?

VW did.
After I cut out the Al from 2mm sheet and made the two bends, I put a stock steel bracket on each side, then squished them together.  It's not ideal because there's no allowance for the thickness of the material, but it does kinda work.

Very cleaver!!

Now, what other parts can you make using that technique?

[Pas]

Another small saving, single skinned the glove box door.

Not sure how much lighter it is yet, need to weigh it.

[Bruce]

Well done.

Don't forget to drill the hinges!

What do you think about making it from alloy?  I think 1.2mm would make it rigid enough.

[Chris W]

[speedwell]

what do you think about those brake drums ,they aren't on a car ,but on a sand buggy ,very light no back plates