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Varg In Jeep's Clothing

Discussion in 'Builds and Fabricators Forum' started by ITLKSEZ, Aug 20, 2015.

  1. Oct 15, 2019
    mortten

    mortten I can’t put my finger on it

    Peninsula, Ohio
    Joined:
    Apr 17, 2006
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    Does it tell you before or after they fail :). Nice work as usual.
     
    Last edited: Oct 16, 2019
    Twin2 and ITLKSEZ like this.
  2. Oct 15, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    3,386
    Right? I think I could tell when my brakes are failing. :D
    I’m using it more as a junction block, but if the sensor is there...
     
  3. Oct 16, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    I found an oversight. I built the front axle without the calipers installed. I threw them on this morning and found that the inlet port dumps really close to the steering arm. I’m not sure I’ll be able to fit the hose in there without using a 90° fitting and shooting it up toward the top knuckle pivot.

    It’s hard to tell in the pic, but the edge of the arm easily clears the hole, but the arm is angled. A rubber hose would have definite contact.

    It’s irritating, because caliper removal after the brake line is on will either require arm removal or line removal. Maybe with a 90° fitting, I’ll be able to clearance the arm so it can slide past.

    [​IMG]

    Also, I really despise running hard brake lines. I really struggle to find the patience.

    Front hard lines are roughed in.

    [​IMG]
     
    47v6 and Fly Navy like this.
  4. Oct 16, 2019
    Rich M.

    Rich M. Shoe pusher

    Maryland
    Joined:
    Mar 23, 2008
    Messages:
    598
    Rotate the caliper brackets 180°?
     
  5. Oct 16, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
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    I like where you’re going, but the caliper bracket *is* the knuckle.

    [​IMG]

    I could swap left/right calipers, but I’d have to remove them and turn them 90° to bleed them. It might be the best option at this point.
     
  6. Oct 16, 2019
    homersdog

    homersdog Tulsa, Ok Sponsor 2019 Sponsor

    Tulsa, OK
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    Jan 8, 2012
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    Is there enough meat in the caliper to tap a new inlet on the top surface?
     
    47v6 and ITLKSEZ like this.
  7. Oct 16, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    I’m researching...

    I’m looking in the direction of using a banjo bolt in the double flare hole. I’ll need a special m10x1 banjo bolt that I don’t have on hand, and I’ll need to machine a flat sealing edge on the caliper housing. Then it’s just a matter of sitting in front of the Rockauto catalog until I find the right hoses.

    [​IMG]
     
  8. Oct 16, 2019
    Snoops

    Snoops New Member

    Idaho
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    Sep 4, 2019
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    Did I read something about vegan jerky here?, awesome skills!
     
    ITLKSEZ likes this.
  9. Oct 16, 2019
    47v6

    47v6 junk wrecker! Sponsor

    Washington DC.
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    Make an adapter to rotate the caliper
     
    Rich M. likes this.
  10. Oct 16, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    It can’t go up or down because of the knuckle bearings. I can’t move them to the front because they’ll hit the coil mounts at full lock.
     
  11. Oct 17, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    I finally got the hard lines on the frame finished today.

    I’ll try to explain what I’m trying here...

    (pre-ABS?) Volvo cars utilized a complex network of failsafes in their braking.
    -The master cylinder has two equal plungers with no F/R compensations built in. Both plungers supply equal fluid at all times. -Each plunger feeds two circuits (four ports on the MC).
    -The Volvo front rotors are twin piston, and the pistons are independent of each other, being fed by two brake hoses to each caliper.
    -The front MC circuit, for example, will feed one of the left and one of the right front pistons, and one rear brake. The rear circuit will feed the other front pistons and the other rear brake.

    With this setup, even with one of the two circuits failed, you’ll still have one rear brake at 100% and both front brakes at 50%. This is the reason for the brake failure lamp. Even with only half the brake system working, it’s possible you could not realize there’s a real problem.

    With that in mind, I went about my brake setup a little unconventionally. I blocked off one front and one rear circuit, and I’ll run the remaining 2 lines to the brake failure sensor as a junction block. From there, the two circuits split to feed the LF/RR wheels, and the RF/LR wheels.

    The front Toyota calipers are 4-piston monsters, and the rear Isuzu Rodeo calipers are single-piston. The difference in piston surface area *should negate the need for a proportioning valve.

    So, from the sensor, I ran two lines front and two lines to their opposing back sides.

    [​IMG]

    Through the frame holes made for this...

    [​IMG]

    And back around the muffler to two separate rubber lines.

    [​IMG]
     
    Twin2 and 47v6 like this.
  12. Oct 18, 2019
    Keys5a

    Keys5a Sponsor Sponsor

    Florida Keys
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    Jan 23, 2014
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    Some of the '90s Land Rovers did the same thing feeding separate pistons in the same caliper from different ports on the master cylinder. Complicated, but redundant; Safety!
    I'll like to see how you machine the calipers to accept banjo washers, if you go this route.
    As always, very nice work!
    -Donny
     
    ITLKSEZ likes this.
  13. Oct 18, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    Donny, I was typing as you posted that. :)

    I researched the threads/pitch I needed for these banjo bolts and located a part number through O'Reilly’s website. I called them, and they had two of them within 2 hours. They were $4 each. Awesome! Picked them up last night.

    I had to machine the faces of these caliper ports flat for the banjo fittings to seal. They were pitted badly. I hit them with some sandpaper just to see what I was working with...

    [​IMG]

    I made a tool out of a flare fitting, two washers and some sandpaper. I cranked down on the fitting and turned the big washer. It took a few pieces of sandpaper to get them to enough bare metal to seal, but it made a nice perpendicular cut.

    [​IMG]

    [​IMG]

    Then I had to cut a big chunk out of the steering arm for the new fitting and hose to pass for removal. Oversight fixed! I’ll have some custom hoses made up when I get a funds refill.

    [​IMG]
     
    73 cj5, Twin2, 47v6 and 3 others like this.
  14. Oct 18, 2019
    Keys5a

    Keys5a Sponsor Sponsor

    Florida Keys
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    Nice job! I always like your outside-the-lines solutions.
    -Donny
     
    ITLKSEZ likes this.
  15. Oct 18, 2019
    Cap-n-Cray

    Cap-n-Cray I want to do this again.. Staff Member Sponsor

    Bainbridge...
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    Sep 21, 2009
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    202,718
    I like it... :clap:
     
    ITLKSEZ likes this.
  16. Oct 18, 2019
    47v6

    47v6 junk wrecker! Sponsor

    Washington DC.
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    Oct 25, 2006
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    Wow, just wow!
     
    ITLKSEZ likes this.
  17. Oct 20, 2019
    Focker

    Focker That's what I do, I know things and I fix stuff. Staff Member Sponsor 2019 Sponsor

    Tri-Cities WA
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    Aug 18, 2014
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    X2
     
  18. Oct 21, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    I took a break from Halloween costumes this morning and decided it’s time to strip it down to the frame, box it, fill holes, finish the welding, and paint it. The front frame horns and bumper are still a big question mark, but I’ll be able to repaint them in-place easily enough.

    [​IMG]
     
    Rich M., 47v6 and jeepstar like this.
  19. Oct 21, 2019
    47v6

    47v6 junk wrecker! Sponsor

    Washington DC.
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    Finish weld that driveshaft!!!where did the engine and transmission go?/
     
  20. Oct 21, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    You were never very good at Where’s Waldo? :D
     
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