I always knew I wanted to upgrade my single break master cylinder to a duel circuit system but was always put off at the price of the CPS kit required to do this, when I first started looking they were £85 and at a Volks World show I saw a kit for £130 so thought I better get the kit from the cheapest stall I could find this was for £119
For what you get this is very over priced, so I never broke into the kit thinking I may be able to put it together cheaper myself. I recently found other parts shops are now making there own less expensive version of this kit.
Having a bit of time while the van was being painted I dug out the duel circuit master cylinder I got from my recent batch of parts purchase, and ordered from e-bay three 90mm x 20mm thick billet aluminium bar for £11 posted.
A set of dividers marked the ruff centre and using an optical punch that uses a Perspex shaft with a cross on the end, once aliened the base is held in position and the shaft is replaced with the punch that once hit provides a very accurate centre punch.
Once I'd swapped the jaws in the lathe chuck to hold a larger piece I centred the billet, drilled a pilot hole then bored it straight through. The CSP spacer has a step I think this is to help keep the gator on
I cut the hole tight enough to seat against the o ring on the face of the master cylinder
Whilst in the chuck I marked the position for the bolt holes.
Once marked I checked there alignment with the master cylinder and also marked the outer profile of the mating surface.
I cut the profile out on my chop saw which is not very accurate, because the table moves when cutting, this led me to under cut the profile a bit. I cleaned up my mistake and rounded the corners with a hand file.
Clamping my grinder the bench with quick clamps I fitted a buffing wheel a tried my first bit of polishing. This was prity straight forward I just had to keep the work under the centre of the wheel and work off the trailing edge so it would not catch the work.
A quick trial assembly
I had to try in on the van once I had it back from paint.
My next query was with the rubber gaiter provided in the CSP kit has a lip to sit in a groove like the original one but because the duel master cylinder is for fitting onto a servo it does not need a boot.
I will look for other boots or cut a groove in my MC so it stays on.
