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Converting The Single Reservoir To A Dual Reservoir Mc In A Fc-150

Discussion in 'Jeep Truck and FC Tech' started by jeepstar, Nov 1, 2019.

  1. Nov 1, 2019
    jeepstar

    jeepstar Sponsor Sponsor

    Sheboygan
    Joined:
    Jun 28, 2006
    Messages:
    1,387
    materials:
    (3) pieces of 3/16" flat stock
    (1) 2"w X 3"l flat stock
    (2) 1 1/2"w X 3"l flat stock
    (1) Wilwood tandem remote dual reservoir master cylinder (part #260-7563)

    the 2" wide flat stock will need a 1 3/8" hole drilled into it, and (2) 11/32" holes drilled in it to mount the the new MC to. i only pre drilled the hole for the hole saw. you can drill or just mark the other holes now, they are the 11/32" dia, and all holes are drilled in a line vertically. i waited until after i was done welding to do the hole saw to minimize deformation.

    below is a schematic of the MC dimensions from the Wilwood site:
    upload_2019-11-1_10-51-44.png

    upload_2019-11-1_11-18-14.png

    when welding together, i only put 2 beads on the inside at each corner. if you try and weld one big seam, it will warp. this is the inside of the mounting bracket. the new MC will mount from the other side.

    upload_2019-11-1_11-19-43.png
    hole drilled and all holes deburred:
    upload_2019-11-1_13-46-14.png

    painted black:

    upload_2019-11-1_13-46-56.png

    holes are off center. This is because the brake pedal and the rod that pushes in to the master is off center.
     
  2. Nov 4, 2019
    jeepstar

    jeepstar Sponsor Sponsor

    Sheboygan
    Joined:
    Jun 28, 2006
    Messages:
    1,387
    i threaded the mounting holes for a 5/16" bolt. then i bolted the MC to the mounting bracket.



    upload_2019-11-4_7-51-15.png upload_2019-11-4_7-51-58.png
     
    Focker likes this.
  3. Nov 4, 2019
    jeepstar

    jeepstar Sponsor Sponsor

    Sheboygan
    Joined:
    Jun 28, 2006
    Messages:
    1,387
    you can use the existing pushrod, you will need to cut the big ball side off, and smooth the edges around the new cut.
    also, you will need to notch a spot for the bleeder valve.

    upload_2019-11-4_8-56-56.png upload_2019-11-4_8-57-38.png
     
  4. Nov 4, 2019
    jeepstar

    jeepstar Sponsor Sponsor

    Sheboygan
    Joined:
    Jun 28, 2006
    Messages:
    1,387
    i reused the pedal support strap that goes from the original bracket to the U bolt on the steering column. had to make 2 notches, one for each bleeder valve. the back one is a notch, the front one is just a hole drilled.

    i drilled 4 new holes, used 4 bolts to bolt the new bracket up plates. once this is all done, i recommend taking it all apart to paint it up nice. also, i would do most of this with the pedal assembly removed bolt it to a board or something.
    i wasn't sure how this was going to work out so i left everything in place and worked from there. also need to find a spot to mount the reservoirs, but its mounted and ready for a disk brake conversion if i take it that far.
    as for the new mounting bracket, you can weld the entire inside seams, just be careful to not deform the bracket. i tried welding the entire seam on my first attempt and it pulled the sides in too much.

    upload_2019-11-4_8-59-26.png
     
    jeepermc, txtoller and Twin2 like this.

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