Things move at the speed of molasses around my place on projects. Too much other stuff going on, my automotive projects always take a back burner.
Anyhow, I went to install the russell lines this evening along with a replacement master cylinder, the main reason for doing all this. Brakes at the wheels all recently redone, i figure this is whats left, and i can bleed it and forget it for awhile.
The grooves for the E clips that clip the lines into the bracket at the frame ends are too wide. This allows that end to move around in the bracket. The groove is actually big enough for 2 E clips to fit in there, so i am going to go buy 2 more of these to secure the lines at the frame end a bit better so its not so loose in the bracket. Also there is nothing to hold the lines close to the upper A arms. I test fitted my tires and turned them full lock each direction and the lines rub the sidewalls slightly. Now granted your not going to be driving full turn all the time, but when you have to make a tight turn in a parking lot the lines will rub the tire. Eventually they will rub through.
I cut the old rubber lines off the OEM A arm support brackets. I have a few ideas one involves using aircraft "Adel" clamps with silicone rubber cushions on them, and cutting those brackets and modding them to accept the new clamps.
I dont suspect i will have this type of problem with the rear line. That part of the install is pretty straight forward.
Now for some wierd crap. When i pulled the hoses off the calipers, and cleaned up the banjo bolts. I went to looking for the copper washers to make sure i had all 4 of em. Made sure they werent stuck to the calipers or the bolts. One bolt i had to remove the washer, there were washers stuck to both brake lines on the sides that goes against the calipers. Only found 3 copper washers. I double checked to make sure i didnt leave one behind when i put the new lines on, yep they are all removed from the calipers and bolts. I am thinking this was put together at the factory this way. I bought the truck brand new in 1994. These caliper banjo bolts have never been off until now. Is it even possible for one of the washers under the banjo bolt head side to be missing and the system not leak?? Because this thing never leaked in the 24 years i owned it, and i only got 3 copper crush washers when i took it apart.