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'62 Falcon Econoline


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So far it has been an easy install. 

 

Very easy.  :thumbup:

 

 

We'll see what a PITA the master cylinder will be in a couple weeks.

 

This looks like a bitch. Hoping it's not...   ^_^

 

Basically there's a big complex bracket under the floor that the pedal attaches to on one end, and the master cylinder attaches to on the other end. And we have to replace that bracket. 

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So I noticed that John didn't post pictures of the chrome center caps installed.  I'm glad because the four crusty lug nuts and one bare stud per wheel look like ass.  So I went online the other night to look for some new lug nuts.  I bought a set... along with a backup camera & monitor, stereo, four speakers (two 6.5" round 3-way and two 6x9 3-way), and an amp.  If I wasn't scheduled to work tomorrow, I might have sprung for expedited shipping, but since I knew I wasn't going to the shop this weekend, I can wait until Tuesday.

 

 

Oh man, I can't wait until Tuesday!

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Tim decided on some snazzy purple lug nuts...

 

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Did some more grokking of the brake system and decided we'll save that for another day...   :rofl:

 

Tim was asking me about what mirrors might look cool, and I really dig the old school VW van mirrors, so we got some of those...

 

 

 

Tim was a little nervous about taking a hammer to a freshly painted van...

 

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That done we got to drilling...

 

Due to the way the mirror wants to mount, we elected to drill a hole straight through the door (both sides). Then we made a bigger hole on the inside to get a socket in there to tighten the nut on the back side of the mirror...

 

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Got the mirror base mounted...

 

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Rooted through my collection of rubber plugs and found two of these...

 

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Popped in the hole we drilled on the inside...

 

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Mirror stem/head bolted on...

 

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And now the other side done as well...

 

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I dig them...   :thumbup:

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Ok, so the master cylinder wasn't as bad as we expected.  Oh, it was a pain in the ass, just not as big a PITA as we feared.  We got all the old stuff out and the new stuff ready to go back in, sort of.  We still need to finger out the remote reservoir and clearance the parking brake bracket for brake lines... oh, and buy brake lines.  But we're getting there.  I've also decided that the main porpoise of the van is to be a camper, sort of thing.  Of course, having the fuel tank filler just inside the door, venting to the sleeping area, was giving me pause.  So last week I bought a pair of remote filler neck thingies (which haven't arrived yet) to install in the sides of the van and two remote filler neck plate thingies (which have arrived) for the saddle tanks.  Now we're going to have to build a false floor so we can route the filler pipes from the walls to the tanks.  Right now, I'm thinking of installing some drawers under this floor for tools, a spare tire, a jack, a cooker, and other things what need storing.  We'll see if those grand plans ever come to fruition. 

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I feel like Tim mostly posts in this thread whenever I don't post Saturday's progress pics on Saturday...   :rofl:  

 

 

New master and bracket versus original...

 

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Old pedal had to be pried out, and the shaft on it that rotates about the master was in rough shape. So we cut it off...    ^_^

 

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Got a bolt that was a super good fit...

 

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Tim welding it on...

 

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Gave it a test, seems to work way smoother than before...

 

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The new master bracket also has a zerk fitting in it so that once it's all in there we can shoot the pivot full of grease so it's butter smooth...

 

Then on to a fresh coat of paint..

 

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Should go back in next week...

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I feel like Tim mostly posts in this thread whenever I don't post Saturday's progress pics on Saturday...   :rofl:  

 

 

 

I post on here indepen... ok, that's almost exactly what's going on.

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I was worried that what the Chinese call "Stainless Steel" might turn out to be cast zinc or something.  No... oh, no no no.  This stuff welded so wonderfully it HAD to be real, honest to goodness, stainless.  Unfortunately, they do say "Water" instead of "Fuel" so we're going to have to get crafty.  

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This disc brake conversion kit is cool, but it does seem to require a lot of modification to the factory parts to make it work. It's not recommended for the neophyte to attempt it...

 

Today's job was making the old e-brake handle play nice with the new bits. First a notch on the tip...

 

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Then a notch in the middle...

 

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Now it at least fits over the new brake lines...

 

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That done, Tim hands me the e-brake and says "clean and paint monkey!". At this time, I notice the handle on it is not exactly stock. It appears as though some previous owner had broken off the stock plastic handle, then cut a piece of conduit pipe, bent it at a 90 degree angle, and welded it on. That would not do.  

 

So then I has an awesome idea!   B)

 

I ask Tim to cut off that goofy mess and tap the shaft...

 

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Then I go into the parts stash and find an old Hurst T handle I've been saving forever, and we tap that for the bigger threads of the e-brake shaft...  

 

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Excellent!  :thumbup:

 

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Then it was time for the monkey to clean and paint...

 

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While that was drying, we finally did the last assembly (I hope) of the bracket/pedal/master combo...

 

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There is one more mod before install, though. Looking through the instructions we realize we also need to cut a notch into the bracket on the frame that holds the master cylinder for clearance...   <_<

 

So here's hoping it all goes in for good next time we are there...    :thumbup:

 

 

Also decided to just go ahead and replace all of the steel brake lines in the van. It will be much simpler in the end than trying to make the stock lines work with all this stuff. Plus they are 55 years old, so...    :rofl:

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We were grokking the master cylinder and bits which came in the kit and discovered that they "left out" one fitting we'd need.  We looked up the part number (and by "we" I mean "John") and found it to be an O'Reilley part.  We fingered out the lengths of pipe we'd need and of what size... yeah, y'all might remember a post I made on my 1200 thread where I said 3/16 is NOT the same as 3/8.  I felt kind of stupid telling the parts guy I needed thus and such adapter and a bunch of lengths of 3/8" brake pipe, then going, "No no no, that's way too big!"  Once he set me straight, I bought lines and unions and the adapter they "left out" of the kit.  When I went back to the shop, I assembled all the lines to the master cylinder, all running straight and spidery of course, and dumped the brake light switch out if its box.  "Oh, lookie here!" I says to myself.  "Here is that adapter they 'left out' of the kit!"  Three whole dollars, right down the drain!  Psh!

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We were grokking the master cylinder and bits which came in the kit and discovered that they "left out" one fitting we'd need.  We looked up the part number (and by "we" I mean "John") and found it to be an O'Reilley part.  We fingered out the lengths of pipe we'd need and of what size... yeah, y'all might remember a post I made on my 1200 thread where I said 3/16 is NOT the same as 3/8.  I felt kind of stupid telling the parts guy I needed thus and such adapter and a bunch of lengths of 3/8" brake pipe, then going, "No no no, that's way too big!"  Once he set me straight, I bought lines and unions and the adapter they "left out" of the kit.  When I went back to the shop, I assembled all the lines to the master cylinder, all running straight and spidery of course, and dumped the brake light switch out if its box.  "Oh, lookie here!" I says to myself.  "Here is that adapter they 'left out' of the kit!"  Three whole dollars, right down the drain!  Psh!

There is a consistency to all your builds

 

That's all I'm going to say about that

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So I was thinking about the remote reservoir for the brake master cylinder and saw a purple catch can from Sickspeed on the Amazons.  I ordered it of course.  Well, I get an e-mail today saying, "...the purple cans are not in stock, would I like a gold or Neo-Chrome one instead?"  I cyphered and figgered on it for a moment and decided to gopher a Neo-Chrome unit.  Meh, it's LIKE purple... sort of.  I'll hide it inside the doghouse and no one will ever kno... oh, wait.  Y'all know.  Dang it!

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  • 2 weeks later...

Our new reservoir (said repurposed catch can) came in so naturally we took it apart...

 

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Tim wanted to install an air vent so we drilled and tapped a hole in the side, and made a vent pipe from an old 1/2" bolt. First drill through the bolt...

 

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Then cut the head off the bolt, screw it into the can, and pop on a filter to keep people and motors and shit out of it...

 

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Also got some new pipe fitting for the "bottom" of it to neck the outlets down to 3/8". Got some 3/8" nipples for the master cylinder too so we can run hoses from here down to there. But more on that later...

 

 

 

Before we can install that, we need to get the master cylinder in the hole. Here's Tim cutting off the corner of the mounting bracket underneath...

 

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And the master cylinder/pedal assembly going in...

 

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Tim also installed some new brake lines but I was distracted by a dog with a puffy tail, so...

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