Berlinetta build and restoration

[scott h]

Re: Berlinetta build and restoration

I wanted to use Kunifer for the hard brake pipes as it's more durable than copper. The drawback, apart from costing more, is that it is harder to work and so requires good quality tools. I managed to borrow some professional brake pipe tools.

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Kunifer has a reputation for being tough to work with, but I found it ok and after a couple of evenings I had made and fitted a set of pipes. I should now have working brakes, fingers crossed!

[scott h]

Re: Berlinetta build and restoration

Fantastic news! In January I sent off the V5 for the Marlin notifying DVLA of the engine change and colour change to blue. I was very apprehensive about this as I have heard stories of needing the V5 from the donor car and engineers reports etc, but I decided that honesty was the best policy. After over two months I have just received the V5 all present and correct.

[scott h]

Re: Berlinetta build and restoration

After looking at several companies for braided brake lines I ordered a set from HEL on Thurs and they arrived yesterday (Wed). I liked the fact that they have stainless fittings as standard, the website is easy to use and the price (when compared to other custom hoses with stainless fittings) is competitive. HEL have a fixed price of £30 inc VAT while other companies have a more complicated system. I think this is a wee bit expensive, especially as Sierra rear disc brakes require two extra hoses on the calipers, but they are made to order and should last a lifetime.

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HEL hoses are covered with a choice of coloured or transparent pvc, I went for the latter. The black heat shrink on each end is a no cost option for extra protection against damage due to flexing where the hose meets the fitting.

[scott h]

Re: Berlinetta build and restoration

Last week, when I was fitting the brake calipers, I had to fit and remove the wheels several times to check clearances etc. It occurred to me that the wheel studs were a bit neat for length, so I did some checking. The wheel nuts turn just over 5 revolutions from being tight until they are removed. A standard wheel nut for a steel wheel turns 8 times from being flush until removal, I reasoned that this is really the recommended amount. So I decided to fit longer wheel studs.

Here are 2 standard studs at the top and 2 longer at the bottom.

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The old studs were removed by a couple of medium hits with a hammer, with a heavy sledge hammer on the rear of the hub to take some of the shock away from the wheel bearing. The new studs were pulled into position using a wheel nut and a spacer.

With the new studs fitted the nuts turn 11 times which should be much safer. The wheels were supplied by Marlin and there was no mention of longer studs being required but at least now I have one less thing to worry about when I'm driving.

[scott h]

Re: Berlinetta build and restoration

Thanks Mike.

[Mike]

Re: Berlinetta build and restoration

Hi Scott

John Sammut used HEL for his Sportster and thought both their service and hoses were top quality - he said they were brilliant to to deal with.

Mike

[scott h]

Re: Berlinetta build and restoration

Thanks Bryan.

[bryannewell]

Re: Berlinetta build and restoration

Hi Scott
When I renewed my Hoses recently I used a company called HEL
If you Google Brake Hoses they pop up quite early on and on their site you can design your own adding from a range of fittings to suit and even the colour if you wish
I found them very easy to deal with and reasonably priced
Regards
Bryan

[scott h]

Re: Berlinetta build and restoration

Thanks. Venhill is one company that I am looking at. Good to get a recommendation.

[hkp57]

Re: Berlinetta build and restoration

I can now measure up for flexi stainless braided brake hoses. Does anyone have any recommendations which company to use to make custom hoses?

I have used Venhill for many years, always a good service.

http://www.venhill.co.uk/content.asp?PageID=343&ThreadID=343

[scott h]

Re: Berlinetta build and restoration

Brakes. In the first life of my Marlin the brakes did not inspire much confidence, although it passed several MOT's. I think that there were two main factors that contributed to the poor brakes; lack of space to mount the servo in the correct position led to a Heath Robinson arrangement to operate a relocated servo (see page 2 of this diary), and the larger overall diameter of the Marlin wheels and tyres compared to the donor Sierra, which puts the brakes at a mechanical disadvantage.

One reason for fitting a smaller, although equally powerful engine, was to allow the servo to mount in the correct position. To address the second problem of larger diameter tyres I decided to fit uprated brakes. A few years ago, when the restoration was just on the list of things to maybe do, I spotted a Sierra XR4x4 in a breakers yard. I knew this would have rear disc brakes, a viscous diff and larger front brakes. When I asked the price and was told £100 for the lot I jumped at it.

I exchanged the calipers for reconditioned ones at my local motor factor.

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Here we see the standard 2 litre front calipers next to the XR4x4 calipers. The calipers are very similar with only different sized pistons.

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Here the 2 litre disc sits on top of the XR item to show the larger diameter.

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The front and rear brakes sitting in position.

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I have also purchased an adjustable limiter for the rear brakes as it would be very dangerous if the rear wheels lock before the fronts.

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I can now measure up for flexi stainless braided brake hoses. Does anyone have any recommendations which company to use to make custom hoses?

[scott h]

Re: Berlinetta build and restoration

Scott you are am inspiration - Starting mine tomorrow - well cleaning up the garage first !!!

Looking forward to another build diary.

[dbazdavies]

Re: Berlinetta build and restoration

Scott you are am inspiration - Starting mine tomorrow - well cleaning up the garage first !!!

[scott h]

Re: Berlinetta build and restoration

Berlis alive! as Brian Blessed may say. Got the engine running thanks to my friendly auto electrician. Next job is to lengthen and shorten wires to get all the components in their final position.

[scott h]

Re: Berlinetta build and restoration

Hi Paul, the bracket is stainless, the thinking behind it was to make it strong enough for the job but still bendable to adjust the gap. I did think about making the mounting hole a slot for adjustment but decided simple is best.
Was in the garage last night and attended to the fuel leak and a coolant leak. Then tried another ECU but still no joy.