DIY Vintage Period Correct Girling Brake Reservoirs

[ehansen007]

This is my second go at making these reservoirs and although there is information out there, a lot of the parts have changed or are unavailable. Here is my write up on this fun little project:

Parts

Cans- Basco- $21 for three cans shipped with tax. https://bascousa.com/metal-cans-and-tins/cone-top-cans/pint-metal-round-cone-flat-can-1-3-4-in-delta.html

Girling Lids and Stickers x3 (no longer water transfer) $74 Shipped https://prdcrrct.com/product/girling-reservoir-lid/?v=0b3b97fa6688.

Actually I just realized you can get better, cheaper stickers here. I didn't notice mine didn't have the white outline. Not sure which is actually correct but I like the white outline better. https://embertonimperial.com/en-us/products/decal-for-girling-clutch-brake-reservoir-austin-healey-100-3000-triumph-tr2-tr3a?srsltid=AfmBOoqH8c922DkjlBaoaHQX2L9g0N9DHoIvb 9hZW9VUMv8OVVQfw44R

Brass 5/16" Bulkhead fittings (or 1/4" if you prefer) x2 pack $22 https://www.amazon.com/dp/B0CNGPBJLK?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

Clamps: made myself for $20 with hardware

Paint- VHT Epoxy paint- $14

Acrylic Clear $14

All in: $155

https://hosting.photobucket.com/677797bc-aff0-46e3-b9f1-28ba6220f625/56237f0a-c60f-4d53-82de-e44301b2d3c5.png

Prepping Cans

Drill it. The metal is thin so best to angle it around a bit to get rid of any flared slag within the hold. This will flatten the hold for a good seat

https://hosting.photobucket.com/677797bc-aff0-46e3-b9f1-28ba6220f625/79de21e9-dc09-4b1e-a284-f8a1629d3138.heic

Insert Bulkhead fittings with washers. I used some fuel-safe RTV to seal it.
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Tighten those suckers down clean the excess off with Acetone
https://hosting.photobucket.com/677797bc-aff0-46e3-b9f1-28ba6220f625/89b4a6e2-fa74-4094-a736-c3dd9ae0e780.heic

Scuff em' with scotch brite pad to get em' roughed up like the one on the left.
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Make up some brackets with some steel strap stock. Drill holes and test fit hardware
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[ehansen007]

Next, mask em' up and shoot em' with etching primer for a good hold. Shoot them with the lids on so as not to get the threads of the can.

https://hosting.photobucket.com/677797bc-aff0-46e3-b9f1-28ba6220f625/f25e68db-403b-4dd8-8379-8cc3cbf0ddf6.heic

Hit the cans and the brackets with the black VHT epoxy paint or any black to be honest...I did a test and it looked like the VHT paint came off pretty quick when exposed to brake fluid. So I tested the Rustoleum Acrylic clear and it helped a lot, it faded a bit but didn't wipe off.
https://hosting.photobucket.com/677797bc-aff0-46e3-b9f1-28ba6220f625/3171c302-ad2f-4fe6-b038-a2061feac2fa.png

Put the stickers on first, THEN clear coat them along with the brackets!
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[GoDadGo]

The Lengths We Go To In Order To Build Our Dream Cars Is Amazing!
...........................The Devil Truly Is In The Details!
...................................Bravo, Bravo & Bravo!

[StangRacer]

Erik...

Thank you for posting this!!

I found another source for the cans. The cost is about the same as the link you posted but shipping is significantly less.

https://www.usplastic.com/catalog/item.aspx?itemid=151701&catid=1343

[Derald Rice]

How well is the paint holding up to the brake fluid ??

[achi]

I've scoured all sites looking for information on the AN fittings etc for these reservoirs. I will order lids from forum vendor. I have had the cans for a while now and am looking at making my own. I think I recall 2fast4U (Bill) had fully documented the parts to complete this but all posts seem to be deleted and I am not sure he is active on this site now. I would so like to know how these reservoirs hold up and if anyone also remembers the thread.

Thanks in advance
Achi