mountainhick
10-05-2013, 12:34 PM
A frustrating day yesterday, and the project extended into this morning.
After a couple days waiting for the parts, I rebuilt my clutch master cylinder yesterday. easy peasy.
Then went to install and noticed the fluid intake tube had broken off. I was completely perplexed. Nothing felt like it broke when I removed the hose, it was not inside the hose, and nowhere to be found.
So, no way to hook up the fluid.
How it should look, note the tube:
http://images.oreillyauto.com/parts/img/large/ba/ba0728855-1.jpg
Mine:
http://www.mountainserver.net/previa/clutchcyl-1.jpg
I looked up the part and called Toyota... part discontinued, not available, but can replace entire master cylinder.
UGH!! I don't want to wait another several days, and I don't want the added expense.
Thought about it for a while and figured with some metal I could turn something on my metal lathe to fit the hole and O-ring seal, but then how to add an elbow?
I went to the hardware store (1/2 hr drive each way, like everything where we live), they had the fuse, so I got a couple for backup, and found parts that could work. If I turned down a 1/2" npt-1/4" npt pipe reducer fitting, added an elbow and flange, I could replicate something like the broken plastic part.
I put in the fuse, and it immediately blew. opened the switch/electrical box on the lathe and it is way beyond my ability to troubleshoot.
So another hour of thought and I came up with a makeshift platform to attach a cross slide vise as tool holder, screwed a pneumatic connector into the 1/4" npt fitting, chucked that into a drill chuck, chucked that into my wood lathe chuck and produced a workable part. It was sketchy and I do not recommend anyone do this. There was way too much play in the chucking and movement in the vise/mounting mechanism. Pretty scary really. But it got the job done.
http://www.mountainserver.net/previa/clutchcyl-2.jpg
http://www.mountainserver.net/previa/clutchcyl-3.jpg
So that's as far as I got yesterday. This morning I found a scrap of brass sheet and cut and drilled a flange:
http://www.mountainserver.net/previa/clutchcyl-4.jpg
That is soldered to the NPT flange and the elbow is soldered in to avoid any leaks:
http://www.mountainserver.net/previa/clutchcyl-5.jpg
It works, but what a silly amount of work and energy over this niggly little part.
http://www.mountainserver.net/previa/clutchcyl-6.jpg
After a couple days waiting for the parts, I rebuilt my clutch master cylinder yesterday. easy peasy.
Then went to install and noticed the fluid intake tube had broken off. I was completely perplexed. Nothing felt like it broke when I removed the hose, it was not inside the hose, and nowhere to be found.
So, no way to hook up the fluid.
How it should look, note the tube:
http://images.oreillyauto.com/parts/img/large/ba/ba0728855-1.jpg
Mine:
http://www.mountainserver.net/previa/clutchcyl-1.jpg
I looked up the part and called Toyota... part discontinued, not available, but can replace entire master cylinder.
UGH!! I don't want to wait another several days, and I don't want the added expense.
Thought about it for a while and figured with some metal I could turn something on my metal lathe to fit the hole and O-ring seal, but then how to add an elbow?
I went to the hardware store (1/2 hr drive each way, like everything where we live), they had the fuse, so I got a couple for backup, and found parts that could work. If I turned down a 1/2" npt-1/4" npt pipe reducer fitting, added an elbow and flange, I could replicate something like the broken plastic part.
I put in the fuse, and it immediately blew. opened the switch/electrical box on the lathe and it is way beyond my ability to troubleshoot.
So another hour of thought and I came up with a makeshift platform to attach a cross slide vise as tool holder, screwed a pneumatic connector into the 1/4" npt fitting, chucked that into a drill chuck, chucked that into my wood lathe chuck and produced a workable part. It was sketchy and I do not recommend anyone do this. There was way too much play in the chucking and movement in the vise/mounting mechanism. Pretty scary really. But it got the job done.
http://www.mountainserver.net/previa/clutchcyl-2.jpg
http://www.mountainserver.net/previa/clutchcyl-3.jpg
So that's as far as I got yesterday. This morning I found a scrap of brass sheet and cut and drilled a flange:
http://www.mountainserver.net/previa/clutchcyl-4.jpg
That is soldered to the NPT flange and the elbow is soldered in to avoid any leaks:
http://www.mountainserver.net/previa/clutchcyl-5.jpg
It works, but what a silly amount of work and energy over this niggly little part.
http://www.mountainserver.net/previa/clutchcyl-6.jpg