The RustBucket's master cylinder was stuck. The rebuild kits cost too much, and I can't wait for the kit to arrive. And I don't have time to re-build it. And, I think I once read about there being more than one piston configuration, so not sure which rebuild kit to buy.
Decisions. Which of these to use. Cheap Chinese master, or re-pop master?
Original RustBucket master and the re-pop. Initially I was going to use the re-pop, but there is too much retrofitting required to get the original brake switch to work:
A recess (red arrow) would have to be drilled to allow the brake switch's flange (green arrow) to fit.
An additional hole (white arrow) would have to be added for the brake switch's alignment pin (pink arrow).
The roll pin from the RustBucket's broken lever (blue arrow) would have to be transferred to a hole drilled into the new lever.
Too much work for this bike. (It later dawned on me that I could use a banjo bolt brake light switch instead of the stock switch, but I had committed to the cheap Chinese master cylinder by then. And, I'd like to save the repop for a nicer bike.)
While on this subject, the lever pivot on the RustBucket was rigged up with these two bolts, one coming in from the top, the other from the bottom.
Both were screwed about half way into the lever's threaded brass bushing. Actually, a pretty clever solution.
This is the correct bolt. It screws fully into the threaded bushing, and has smaller threads on the end for a nut to hold the brake light switch on. Readily available for about $5 shipped on eBay.
But, I used this master cylinder. No muss, no fuss.
They are so cheap, and so indispensable in an emergency, that I always keep one of these masters on hand. Here's the current cheapest link:
https://www.ebay.com/itm/262581136299
I've probably used about a dozen. They used to be as cheap as $10, but you had to wait for shipping from China. Now, the price has skyrocketed to $15.39, but they ship from the U.S. That's about 1/4 the cost of the stock master cylinder rebuild kits. Mikes XS sells what appears to be the exact same Chinese master cylinder for $84.
I re-built the caliper back in post #49. Used a seal kit from the U.K., and re-used the pitted pistons after re-conditioning them some. So far, everything is good. Brake works great, and no leaks at the caliper. So far...
Decisions. Which of these to use. Cheap Chinese master, or re-pop master?
Original RustBucket master and the re-pop. Initially I was going to use the re-pop, but there is too much retrofitting required to get the original brake switch to work:
A recess (red arrow) would have to be drilled to allow the brake switch's flange (green arrow) to fit.
An additional hole (white arrow) would have to be added for the brake switch's alignment pin (pink arrow).
The roll pin from the RustBucket's broken lever (blue arrow) would have to be transferred to a hole drilled into the new lever.
Too much work for this bike. (It later dawned on me that I could use a banjo bolt brake light switch instead of the stock switch, but I had committed to the cheap Chinese master cylinder by then. And, I'd like to save the repop for a nicer bike.)
While on this subject, the lever pivot on the RustBucket was rigged up with these two bolts, one coming in from the top, the other from the bottom.
Both were screwed about half way into the lever's threaded brass bushing. Actually, a pretty clever solution.
This is the correct bolt. It screws fully into the threaded bushing, and has smaller threads on the end for a nut to hold the brake light switch on. Readily available for about $5 shipped on eBay.
But, I used this master cylinder. No muss, no fuss.
They are so cheap, and so indispensable in an emergency, that I always keep one of these masters on hand. Here's the current cheapest link:
https://www.ebay.com/itm/262581136299
I've probably used about a dozen. They used to be as cheap as $10, but you had to wait for shipping from China. Now, the price has skyrocketed to $15.39, but they ship from the U.S. That's about 1/4 the cost of the stock master cylinder rebuild kits. Mikes XS sells what appears to be the exact same Chinese master cylinder for $84.
I re-built the caliper back in post #49. Used a seal kit from the U.K., and re-used the pitted pistons after re-conditioning them some. So far, everything is good. Brake works great, and no leaks at the caliper. So far...
Last edited:
