[ROVERNET - UK] Brake & clutch cylinder sleeving [was P6 Clutch master cylinders]

S Manwell s_manwell at alum.swarthmore.edu
Fri Mar 9 14:38:00 GMT 2007

As Pete suggested, don't forget the option of getting a clutch master 
cylinder (or any other hydraulic cylinder) sleeved in stainless steel or 
brass.  Typically the process is that you disassemble the cylinder and 
ship the bare cylinder casting to a specialty machinist.  The casting is 
then grit blasted to remove all the rust inside and out, then the 
cylinder is bored to a larger diameter, then a sleeve with the same 
inside diameter as original is pressed in.  Finally, the holes are 
drilled through the sleeve wherever there is a fluid port on the 
original cylinder.

The last step brings up an issue with rebuilding a clutch master for a 
Federal 2000TC.  The fluid inlet port into the cylinder from the saddle 
tank is offset from the opening on the top of the tank where the hose 
from the reservoir connects to this saddle tank.  One solution is to 
drill a temporary hole in the saddle tank in line with the port into the 
cylinder.  After drilling the hole into the sleeve, then the temporary 
hole can be capped.  I believe we did this by screwing a very 
small/short screw coated with epoxy into the hole -- this is the brake 
fluid is not under pressure in this area.

When the sleeved cylinder is returned to you, then you or your mechanic 
assembles it again using a new rubber seals from a rebuild kit.  The 
sleeving service costs $50 to $60 for most cylinders, more for 
complicated ones like servo cylinders or tandem master cylinders.

I can recommend a machinist specializing in brake sleeving in stainless 
steel and with experience with Rover cylinders including the Federal 
clutch master:
Mark Frappier
82 Mountainview Drive
Agawam, MA  01001

Also, I believe it was Sierra Specialty in California 
(www.brakecylinder.com) that others on this list have recommended for 
this service.

I have never had a problem with a cylinder after it was sleeved -- the 
sleeve is corrosion proof, unlike the mild steel or aluminum of an 
original cylinder.


>  Early Pt# being L4223-934 or 725 depending on whick book you
> use , and the late  Pt.# is  L4211-139  or  112 again depending on when
> the book was printed. 
>       The bad news is that these are the only ones I can find new( there
> are rebuilts out there ) so I can't let them go too cheaply, sorry. I need
> $200.00 apiece for them . 

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