924Board.org

[Patrick]

Hi All!
I finally put in new brake fluid reservoir Rubber Plugs on my master cylinder with some effort.

But when i finally tried to mount my old plastic reservoir into the master cylinder, it seemed to me that because of the tightness of the new rubber plugs, the two nipples were getting bent too acutely (at the portion that meets the plastic reservoir), and being that its an old reservoir, i decided not to force it, lest i risk braking it!

No available reservoirs over here, old or new...Besides, i`m on a budget. I in fact did my best to direct the force on the reservoir as perpendicular as possible to the master cylinder.

So i`m thinking of putting in one nipple at a time so i can concentrate on it and in fact have someone watch the nipple to ensure it is going straight in and not bending dangerously.

I`m thinking this might work since that is how i removed the reservoir, by pulling out one nipple first and then the other, possible because of the amount of play that the rubber allows the nipple (without putting undue stress on the nipple). What do you guys think? Has anyone done it this way? Thank You!
patrick
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1979 924 U.S. version
Single sidedraft Weber 40

[PORSCHEV]

The reservoir is pretty tough. I just put a little brake fluid on the rubbers for lube...and they push right on.
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1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.

[stevekat]

Make sure the rubbers pieces are fully seated and use lubrication as Porschev indicated.
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"Never get out of the boat. Absolutely goddamn right. Unless you are goin' all the way."

Gone to new home: '81 924T, US version, CGT Intercooler, UTCIS-PT, Euro DITC, Greddy Trust MBC, Forged Fuchs Flat Dish 6's, Factory Recaro's.

[Patrick]

I guess i have to soak the rubber pieces liberally with brake fluid. Thanks guys!
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1979 924 U.S. version
Single sidedraft Weber 40

[Patrick]

Ok, i filled up the two rubber pieces with brake fluid to help the two plastic nipples go in more readily. But one end is really stubborn, to the point that the nipple bends acutely to one side. In fact i even tried putting that stubborn side on first, but still no luck!

First of all, i have to admit that i could not source the two rubber pieces (plugs) locally, so i got whatever other VW pieces were available locally. Thing is, i was told by the seller that these locally fabricated pieces were made of harder and less flexible rubber.

So i believe there are two possible reasons why the nipples have an extremely difficult time going in (i lucked out with one nipple though): 1- as stated, rubber was hard and had less "give" to allow nipple entry and/or 2- Inner Hole diameter of the rubber piece might be smaller than the factory rubber, so that the "ring" at the end of the nipple just could not go in.

My possible solution: Decrease the Outer diameter of the "ring" at the end of the nipple just enough to allow the "ring" to go through the rubber, but not so much that the "ring" doesnt seal properly the bottom end of the rubber piece. I plan to use relatively fine grade sandpaper for this.

My Question: So is it ok to decrease the Outer Diameter of the "ring" i described? Can i safely assume that the "ring" at the end of the plastic nipple in fact just protrudes out the bottom of the rubber plug and forms a seal with the bottom portion of the rubber plug, and that decreasing its diameter would not prevent it from properly sealing with anything else in the entrance of the Master cylinder?

Your soonest replies would be appreciated as i hate to leave the brake fluid exposed (i just wrapped some plastic around it) to what is a very high humidity environment for too long. Thanks Again,
patrick
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1979 924 U.S. version
Single sidedraft Weber 40