Lotus Elan brake help - no pedal

[hardcastlephil]

Hi all,

Posting on behalf of my father here - He is restoring (has been for about 10 years) a 68 Lotus Elan DHC. Just been to see him today, and he's reached the point where he is stuck and shouting about selling the project/giving up etc - happens to us all! Although I'm keen to help him as I want to see it on the road too!

Bit of background in my old man, he was a mechanic for years and owned numerous elans - so knows the basics, however I wouldn't put it past him to get so annoyed he won't have checked the obvious - so all ideas welcome.

So here are the facts:

He has no brake pedal pressure.
He has narrowed it down to an issue with the fronts - as when he clamps off both front flexi-hoses (just before caliper), there is excellent pedal pressure.
If he clamps of either one of the front hoses, there is better pressure, but not enough (second pump of pedal)
The car has new everything - servo, cylinders, brake lines, flexi hoses.
Calipers have new pistons and seals
There is no leakage evident from the calipers - appear bone dry

So, any ideas? I guess that as both front flexi hoses have to be clamped, it means both calipers or hoses have an issue? I had thought about the servo, but obviously not if there are no issues with the hoses clamped.

He's reluctant to go and buy new calipers, when these are not leaking and have been refurbed (and he's a tight Yorkshire man!). Based in East Yorks if that matters.

All help welcomed,

Phil

[gforceg]

Did the pop up headlights work on the brake system pressure or am I thinking of something else?

Have the brake pads been put back in?

Did he rebuild the calipers himself? Could fluid be getting past seals without leaking out?

I imagine someone will be along soon with some better ideas...

Good luck.

[Raize]

hardcastlephil said:

However I wouldn't put it past him to get so annoyed he won't have checked the obvious - so all ideas welcome.

Bleed the air out of the pipes.

[GadgeS3C]

Raize said:

Bleed the air out of the pipes.

Had a similar problem and couldn't bleed the air out of the calipers by the traditional method. Bought a Gunsons Eazibleed and sorted it in 5 minutes.

Well worth a try if he hasn't already.

[hardcastlephil]

Thanks chaps,

Yes - he's bled and bled - also bought an eazibleed too, but to no avail!

Like the idea of fluid/air getting past the seals but not out...

P

[spaximus]

If it has been stood for 10 years, even a new master cylinder could now be faulty. If it has been fitted and left open to the air, then corrosion builds up and when you fill with fluid and pump the pedal, the seals get torn on the inside of the MC.

I would also make sure that the push rod is not too long on the MC. If it is the cylinder may well not have full stroke.

I would begin by bleeding the MC via the pipes at the MC first, then on the servo and finally down at the calipers. If you still have no pressure with no air escaping then I suspect the fault is the MC

[Slidingpillar]

Not something daft like fitting the right hand calliper to the left side and visa versa? (Bleed screw thus not at highest point).

If all is correct, try a bleed having sidestepped the brake pedal, jerk things into action.

[grumpy52]

May sound stupid but check the seals in the calipers are fitted the correct way round .
Something easily done wrong but only done once .Five days it took to find and yes I had already replaced the calipers.