Hydraulic Brakes - Need Help Please

[Jdauble]

I am working on the Wilwood pedal box on my MK4 Roadster this weekend. I purchased an extra Master Cylinder and reservoir from F5, but that is about the extent of my plans and knowledge of hydraulic brake systems. How much of the F5 instructions do I follow and where does the customizing start during the pedal box build? I’m sure there is already an existing build thread on the subject- could someone help the noobie out please?

Thanks, Jeff

[Papa]

Adjust the balance bar per the FFR manual. There really isn't any customization to the Wilwood pedal box outside of shorting the master cylinder push rods as needed to allow the pedal to fully release and not rest on the chassis cross brace in the foot box. I also attached the pedal pads offset to the left of the pedal to give a bit more room for my wide foot to fit on the accelerator pedal without hitting the brake pedal.

[Jdauble]

Thanks Papa,
I was just reviewing your build thread and admiring your work last night, trying to get some ideas. And yes, grandkids are the BEST!
Did you install any of the clutch quadrant parts or quadrant stop screw per manual clutch instructions? Guess I’m still confused about what exactly to install.

Thanks, Jeff

[Papa]

I installed the quadrant and stop and used the supplied cable. I did make a change to the stop and used a longer bolt to give me the pedal position adjust I needed. I also installed a bulkhead mounted clutch cable adjuster to allow me to tweak the play in the cable without getting under the car.

[Papa]

Also, if you are doing separate reservoirs for the front and rear, just run separate supply lines from the reservoirs to the master cylinders and ignore the plumbing instructions in the manual.

[edwardb]

I guess I'm confused by your question. What was the purpose of the extra master cylinder you bought? Maybe talking about a hydraulic clutch?

[Jdauble]

Yes, thanks. Assuming that I do not need to install any of the clutch quadrant parts because I’m going the route of a hydraulic clutch... but all I have is the extra MC, no instructions and little knowledge. ��

[edwardb]

Yes, thanks. Assuming that I do not need to install any of the clutch quadrant parts because I’m going the route of a hydraulic clutch... but all I have is the extra MC, no instructions and little knowledge. ��

You'll install the brake master cylinders and set up the Wilwood pedal box for the brake and balance bar exactly like the Factory Five and Wilwood instructions. Since you're going with a hydraulic clutch, you won't use any of the Factory Five parts to modify the clutch side and use a cable. Just bolt the master cylinder in like the brake ones except it's a direct connection obviously. No balance bar. You won't find instructions for a hydraulic clutch because that's a mod outside the Factory Five manual. Your final setup depends on what you're going to do for the slave side at the clutch. The Mike Forte kit is commonly used. I've used it a couple times. It's matched to your bell housing and transmission setup. Kind of a little unusual to pick a clutch master cylinder without also knowing what you're doing on the slave side of the equation since they have to work together. Maybe you've already taken that into account. Mike's kit normally comes with a matched master cylinder BTW.

[Jdauble]

Thank you, this helps connect some of the dots for me. Short version, I jumped the gun on the extra MC from F5, and they were happy to take more of my money. �� I’m putting off my motor / tranny purchase until next year, and obviously need to chat with Mike Forte. Thanks for sharing your wisdom.