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Mono Master Cylinder Replacement

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erichdtrombley(at)juno.co
Guest

Posted: Tue Jul 16, 2024 5:35 pm Post subject: Mono Master Cylinder Replacement

I had been meaning to post this to the forum and Area-51’s email jogged my memory.  I recently replaced the original mono master cylinder with a unit that has a built in reservoir.  See photo.  I never liked the idea of continuously bringing DOT3 brake fluid into the cabin to top off the master cylinder due to brake pad wear.   The new unit has more than enough brake fluid capacity in the reservoir such that it shouldn’t require refilling even with completely worn down brake pads.



Since the new unit mounts forward of the original, I fabricated a rail in order to utilize the original mounting holes in the tunnel.  This left room for the installation of a hydraulic line-lock parking brake. The plunger of the line-lock uses the existing filler hole on the top of the tunnel.  The side of the classic cockpit module tunnel is approximate 15 degrees off vertical.  To allow the plunger to be perpendicular to the top of the tunnel I canted the line-lock by the same amount on the mounting rail. See photos.   



The new master has a smaller piston which really improves brake performance.  It’s really quite remarkable.   I am finally able to hold the plane without undue effort during the run up when cycling the CS prop at 4300 rpm.  In fact, the parking brake holds up to 5000 rpm.   So happy to be rid of the wedge I use to stuff into the slot as a makeshift parking brake. The operation of the line-lock is so simple; pull back on the brake lever and simultaneously depress the plunger, then release brake lever.   To undo the parking brake simply pull back on the brake lever.  That’s it.  And the beauty of the design is such that you can’t inadvertently set the parking brake.  



I did have to replace the spring, which serves to push the plunger back up, with a softer one as the original one wouldn’t allow the plunger to remain depressed when I released the brake lever.  Additionally, I replaced the original bulky rubber knob on the plunger with a low profile one (just a screw actually).  Came out nice IMHO.



I purchased the unit from AliExpress for less than $10 US.  The Jamar parking brake was a bit more expensive at $60, although knockoff are out there for much less. 



Erich Trombley

N28ET

Classic Mono 914 

E-Props CS

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trevord

Joined: 10 Jul 2018
Posts: 36
Location: Auckland

Posted: Tue Jul 16, 2024 6:17 pm Post subject: Mono Master Cylinder Replacement

Thanks Eric,



I might buy these parts in anticipation of a future upgrade - thanks for the detailed information.



Regards

Trevor



On 17/07/24, 1:42 PM, "Erich Trombley" <owner-europa-list-server(at)matronics.com on behalf of erichdtrombley(at)juno.com> wrote:



    I had been meaning to post this to the forum and Area-51’s email jogged my memory.  I recently replaced the original mono master cylinder with a unit that has a built in reservoir.  See photo.  I never liked the idea of continuously bringing DOT3 brake fluid into the cabin to top off the master cylinder due to brake pad wear.   The new unit has more than enough brake fluid capacity in the reservoir such that it shouldn’t require refilling even with completely worn down brake pads.



    Since the new unit mounts forward of the original, I fabricated a rail in order to utilize the original mounting holes in the tunnel.  This left room for the installation of a hydraulic line-lock parking brake. The plunger of the line-lock uses the existing filler hole on the top of the tunnel.  The side of the classic cockpit module tunnel is approximate 15 degrees off vertical.  To allow the plunger to be perpendicular to the top of the tunnel I canted the line-lock by the same amount on the mounting rail. See photos.   



    The new master has a smaller piston which really improves brake performance.  It’s really quite remarkable.   I am finally able to hold the plane without undue effort during the run up when cycling the CS prop at 4300 rpm.  In fact, the parking brake holds up to 5000 rpm.   So happy to be rid of the wedge I use to stuff into the slot as a makeshift parking brake. The operation of the line-lock is so simple; pull back on the brake lever and simultaneously depress the plunger, then release brake lever.   To undo the parking brake simply pull back on the brake lever.  That’s it.  And the beauty of the design is such that you can’t inadvertently set the parking brake.  



    I did have to replace the spring, which serves to push the plunger back up, with a softer one as the original one wouldn’t allow the plunger to remain depressed when I released the brake lever.  Additionally, I replaced the original bulky rubber knob on the plunger with a low profile one (just a screw actually).  Came out nice IMHO.



    I purchased the unit from AliExpress for less than $10 US.  The Jamar parking brake was a bit more expensive at $60, although knockoff are out there for much less. 



    Erich Trombley

    N28ET

    Classic Mono 914 

    E-Props CS

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_________________
Trevor

Area-51

Joined: 03 May 2021
Posts: 397

Posted: Tue Jul 16, 2024 9:23 pm Post subject: Re: Mono Master Cylinder Replacement

Thanks Eric, that all looks amazingly simple; have been thinking of installing a line locker... super nice cockpit too!



How is the fluid reservoir accessed?

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erichdtrombley(at)juno.co
Guest

Posted: Wed Jul 17, 2024 5:26 am Post subject: Mono Master Cylinder Replacement

Thanks.  Yes, the setup is remarkably simple.  The only way to access the reservoir is to remove the mounting screws and lower the assembly.  Fortunately, this should only be required for a complete fluid change.  During normal use the rubber telescoping diaphragm on the top of the reservoir allows for the transfer of brake fluid from the master to the slave cylinder to accommodate brake pad wear.  When it’s time to replace the pads, simply compress the puck back into the slave cylinder forcing the fluid back up into the master cylinder reservoir. 



Also, during the brake bleeding process, I found it much easier to remove the entire system (master, parking brake, slave, and brake line) as an assembly from the airplane.  Fortunately, there is sufficient room to fish the slave cylinder through the landing gear mounting frame to allow removal of the assembly.  😅

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Duncan McFadyean

Joined: 18 Jan 2011
Posts: 220

Posted: Wed Jul 17, 2024 12:08 pm Post subject: Mono Master Cylinder Replacement

I did something very similar using a trials bike rear master cylinder, but with a remote and accessible reservoir mounted in the top rear corner of the passenger footwell (but could have been put anywhere).



Duncan McF.

 	  Quote: 	
		   On 17/07/2024 14:24 BST Erich Trombley <erichdtrombley(at)juno.com> wrote:

 

  

 

 

 Thanks.  Yes, the setup is remarkably simple.  The only way to access the reservoir is to remove the mounting screws and lower the assembly.  Fortunately, this should only be required for a complete fluid change.  During normal use the rubber telescoping diaphragm on the top of the reservoir allows for the transfer of brake fluid from the master to the slave cylinder to accommodate brake pad wear.  When it’s time to replace the pads, simply compress the puck back into the slave cylinder forcing the fluid back up into the master cylinder reservoir. 

 

 Also, during the brake bleeding process, I found it much easier to remove the entire system (master, parking brake, slave, and brake line) as an assembly from the airplane.  Fortunately, there is sufficient room to fish the slave cylinder through the landing gear mounting frame to allow removal of the assembly.  😅

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Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

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justin(at)systemwise.co.u
Guest

Posted: Sat Jul 20, 2024 5:49 am Post subject: Mono Master Cylinder Replacement

Hi All

I used a mountain bike brake leaver with integral master cylinder. I mounted it on the control column so that the lever was to hand without removing your hand from the stick. A great success, the volumns of the master cylinder matched the Europa brake slave. Only think is to top up you have to take the device from the control column by undoing the handle bar bracket and bending it over to access the reservoir with gravity directly underneath it. I top up annually at Permit time but it never needs much. Too much going on in a mono on touch down to operate two levers with one hand in my book.

Cheers

Justin



Justin Kennedy

Chairman of the East of Scotland Strut

Owner G-ZTED Mono Europa Classic, Rotax 912S with Airmaster CP Prop.

Justin Kennedy

0131 313 0707

justin(at)systemwise.co.uk

SystemWise Ltd

105-107 Saughtonhall Drive

Edinburgh, EH12 5TS





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