urq brake UPGRADE! was Re: '82 urq: Uneven Brake Pad Wear (right to left)

[John Karasaki <johkar@teleport.com>]

Sorry that I haven't posted this sooner, but I've been swamped.

The brake upgrade is a great success!  Those Girling 60 dual piston
calipers I installed last year really did need an upgraded master cylinder,
too.

I did not take Mike's advice to run without a rear proportioning valve; I
was too chicken to do so after brake horror stories from other list
members.  Instead, I installed a Wilwood manual adjusting proportioning
valve in the brake line going to the rear of the car.

I did tests at full flow to the rear and 57% restricted flow and can say
this:  In the dry, the rear of my urq stops great with full line flow!  In
the wet, however, the rears had a tendency to lock up easily.  Full line
pressure at the rear wheels is dangerous, IMHO, on any moist/wet road.  It
was very unsettling trail braking with full line pressure back there!

The '91 200q master cylinder was a direct bolt on.  FYI, the 5ktq master
cylinder will work, but you have to modify the booster slightly.  I did not
want to do that.

An added bonus of the updated MC is the revised brake fluid reservoir.  It
is much easier to fill and keep topped up during brake bleeding.

If you are contemplating this upgrade, save yourself the grief and use a MC
from a '90 200 that has 4 brake line connections.  The '91 200/V8 MC only
has 2 brake line connections, so I had to fabricate a few (3) brake lines.
Oh, and your standard double flare tool can't make the inverted flare lines
that Audi uses!  Don't bother with this; buy the correct part to start!

Special thanks to all who helped with this project including:  Ben Howell,
Alex Neckas, Chris Tucker, Steve Eiche, and Scott Mockery.

Steve, Chris, and Ben, thanks for the information and inspiration.
Alex thanks for busting your butt to get me the MC at the last minute days
before the PIR event!
Scott thanks for being there with reality checks!  When things don't work
right away, I get wacky!

Always in search of better braking,


John Karasaki

At 12:12 PM 12/17/97 PST, you wrote:
>>Is that device right under the master cylinder the proportioning valve?
>>Did you have to fabricate new brake lines to handle this deletion?  Any
>>details are appreciated.  TIA.
>>
>John,
>Correct on the location.  It's been a long while since the conversion 
>was done.  I believe that I ran 1 line directly into the MC, while I 
>needed a small, 10", fabbed, (on the spot) line for the other link.  I 
>was gong to put in Wilwood variable prop valve but liked the feel 
>without so wll that I kept it!  I'll take a look this weekend and maybe 
>grab a photo.
>Mike
>
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