Tools You Can't Buy

[terry_g]

I have a truck in the shop with Meritor Full Pressure hydraulic brakes. The brakes need to be bled after a component replacement.
The manual says not to manually bleed it it must be pressure bled. I need an adaptor to pressurise the brake reservoir. The Meritor manual
does not give a source for one and the Snap-On dealer can't supply one so I made one. I bought an 18" length of 2" round aluminium and
spent a couple hours machining the lock ring. It was a real pain machining the bayonet lugs. A 1/8" end mill running at 900 rpm. I cut a snap
ring groove in it to make it in two pieces.

The finished lock ring waiting for some final deburring. A little touch up with a file and the ring fit the reservoir perfectly.

Made the rest up and pressed it together. The manual says to put 35 PSI in the plastic reservoir and if you have difficulty bleeding the brakes raise
the pressure to 45 PSI. I think I will do that with the hood closed.

 

[jcdammeyer]

I have a truck in the shop with Meritor Full Pressure hydraulic brakes. The brakes need to be bled after a component replacement.
The manual says not to manually bleed it it must be pressure bled. I need an adaptor to pressurise the brake reservoir. The Meritor manual
does not give a source for one and the Snap-On dealer can't supply one so I made one. I bought an 18" length of 2" round aluminium and
spent a couple hours machining the lock ring. It was a real pain machining the bayonet lugs. A 1/8" end mill running at 900 rpm. I cut a snap
ring groove in it to make it in two pieces.

View attachment 36666

The finished lock ring waiting for some final deburring. A little touch up with a file and the ring fit the reservoir perfectly.
View attachment 36667
Made the rest up and pressed it together. The manual says to put 35 PSI in the plastic reservoir and if you have difficulty bleeding the brakes raise
the pressure to 45 PSI. I think I will do that with the hood closed.

View attachment 36668

View attachment 36669

Wow! Nicely done.

 

[Susquatch]

I think I will do that with the hood closed.

Too funny! But good idea!

Nice adapter! How did you do the taper on the locking ramps? Looks like a difficult feature to do without CNC. I picture a complicated setup with the lock ring at an angle to cut that ramp....... A great butt cheek leak test.

 

[DPittman]

Nice job!

 

[Dan Dubeau]

Great job. You never know what you're going to find in a bar of material sometimes!

 

[jcdammeyer]

Too funny! But good idea!

Nice adapter! How did you do the taper on the locking ramps? Looks like a difficult feature to do without CNC. I picture a complicated setup with the lock ring at an angle to cut that ramp....... A great butt cheek leak test.

The one darker picture on the right shows what looks to be something lifting that side of the rotary table up a tiny bit. And there's a faint shadow on the bottom left under the rotary table. So I'd guess it's tilted.

Move tool under tab. Plunge to thickness depth. Turn until tool leaves tab. Raise tool. Rinse and repeat on the next.

 

[Susquatch]

Move tool under tab. Plunge to thickness depth. Turn until tool leaves tab. Raise tool. Rinse and repeat on the next.

Ya, kinda what I figured. Still very tense moments.....

 

[terry_g]

The rotary table is not tilted it must just be the light. Being the adaptor seals in the neck
of the reservoir it doesn't need to have ramps to make it seal.

 

[terry_g]

I made a second pressure cap last night for the Hydro Boost reservoir. Its dimensions are
slightly different from the Full Pressure System. It will get tested next week.

 

[Lightspeed Mike]

I'm impressed. Very nicely done.