Kiwibirdmans 1962 EJ Holden Wagon

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Been working may way through the list. One of the things was the bracket for the brake booster had to come off and be checked, needs to be TIG'd and crack tested. That is OK.

When I was pulling it apart there was brake fluid coming out the of the back end of the master cylinder into the booster. Also found that the booster had travel from when the brake pedal is pushed to when the master cylinder is engaged ( a gap somewhere in the booster). I had rung Sterling brake and clutch in Onehunga and Saturday and they were helpful and said bring it in we can pull it apart and have a look. 

This morning I went over there, via Zebra pick a part to get another master cylinder off a VZ commodore, cheaper to get another one than try and fix the leaky one. At sterling I got educated on boosters and new master cylinders. The VZ master will not work with the Gemini Booster. There goes Plan A. Plan B is now a new 7 inch Booster and new GM style Master cylinder. On order and has to come from Aus, there are non in the country that are at a reasonable price.

I did get quite a few things sorted out on Saturday. Bolts changed for longer ones, Spring washers added, Lock nuts added. It all takes time.

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The Booster and master turned up pretty quickly from Oz. The shaft on the booster is shorter than the Gemini one, so it will mount directly to the firewall. All good except the wiring loom gets in the way. Found that there is a place near where I can put another hole and run everything through.

I disconnected everything, felt very pleased that I had put plugs on anything that interconnects between the power train loom and  the car loom. The challenge is that the plus on the relays are too big to go through the old hole in the firewall. Looks like having to separate out the connectors from the plugs, not difficult, just a pain.

Also needed another hole saw, ordered on line with the Bunnings click and drive. Only 4 hours later to pick up a single 38mm hole saw. Fucking lock down!!

The other challenge is the master cylinder I got from VPW was the one with outlets on both sides. I had made a point of ordering the GM LHS only type. The RHS outlets hit the bonnet springs. I might have to steal the master cylinder off my Firebird. It is a lot smaller and should be OK.

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A long overdue up date. I stole the master cylinder off the firebird, which was stuffed from having sat for nearly 3 years. Off to Sterling Brake and Clutch for a rebuild, the 3rd time in 25 years.

Here is the booster mounted. And then with the master cylinder and brake lines.

image.png.98f2223fca5c8b16d5865ca346f18269.png  image.png.da91a27445d7a432de6cb5fb70493fa9.png

The brake lines were made out of a copper alloy tube that the brake guys said is all good for cert and way easier than steel to work with. They were not wrong.

The brakes work really well. First hard stop had my 16 year old son complaining that I was going to put him through the windscreen. Had a couple of lock the brake test on the road outside the local school one weekend. Got the serious evils from the lady across the road.

I had 2 of my HQ rostyle wheels widened by the steel surgeon and then all 4 powder coated. 


Masking for the painting. This is pig of a job and took about an hour per wheel. I have done both the fronts and one of the back wheels.






I'm pretty happy with the final result. I bought new chrome wheel nuts and cleaned up the centre caps. Only have 3 so if anyone has one floating around I will gladly swap for some cash.

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