I want to remove both brake boosters on my Federal dual brake system Plus 2. I wish to replace the master cylinder with a smaller bore unit to retain reasonable brake feel and pedal effort without the boosters. I have read over info in the archives, but remain confused on a few points. Most of the posts are several years old, so I expect folks have better experience with their set-ups and parts availability options may have changed? Sorry for the length of the post, but trying to clarify this part clearly in my own mind. Grateful for any corrections, omissions, etc.
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What bore tandem master cylinder would be appropriate for this application? I read that 5/8" (0.625") is the setup on the two seater Elan, but I think this is for the single master setup, not the tandem? Perhaps this is more appropriate for the smaller two seater stock rotor size than for conversions to Plus 2 brakes?
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Alternatively, appears some have used 7/10" (0.700") bore. The Dave Bean catalog calls up this size as p/n 036J_0628 for use in the S3/S4 & Sprint, Europa S2. Not sure if this is just a matter of availability, or a preferable size to the 0.625"? Perhaps the 0.700" is designed for use with boosters and the 0.625 is preferable for no booster setup? The above p/n appears to have the same casting number, bore size, rebuilt kit, flange, etc. as the call-up for Cortina GT 10/66 to 9/67 (non-servo) p/n 028J_0681. Is there a Girling p/n call-up that would more accurately nail down this apparently common part?
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Are direct replacement Girling tandem master cylinders available? I have a few leads on some suppliers from the archive remarks, but without the part number or original application details for the above sizes, I am not sure what to ask for. As I will have to order from a supplier outside of Canada, it is very helpful if I can be completely specific on the part number required, as it is probably not practical to return it if incorrect.
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I checked out the Tilton site as this manufacturer was mentioned in the archives. Not sure if folks that have used the Tilton installed single master as per British/Euro setup, or if they offer a tandem setup. Is the Model 74 Tilton an appropriate tandem cylinder that would offer direct bolt in? I think it is a tandem cylinder from the detail drawing (dual outlet ports), but I am not sure.
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The Tilton 74 cylinder appears to have dual AN3 output ports. Is this the correct size for the Lotus application? Does one use a bubble flare for connection?
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Re-sleeving of the existing M/C component was mentioned as an alternative, primarily at White Post Restorations. Any follow-up info from folks that have used this alternative? I am not adverse to the re-sleeving. However, I would prefer to just get a new replacement part (if available) in case things don’t work out with the modified setup; this would allow me to re-install the stock system with the existing parts.
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Would I retain the pressure differential valve (Lotus p/n 50_J_6053) in the revised setup?