1966 Ford Galaxie 500 XL Refurbishment : 098 Custom LIghted Window Switches - Design, CAD and Assembled


2023, November 14

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Next up are the parking brake cables and hard hydraulic lines.

The parking brake cables are 94-96 full size Chevrolet parts. I just made clamps to hold the cable nicely. All hard lines are stainless.

Adjusting the cable so it doesn't get to close to the exhaust.

Otherwise I ran them like the factory '94-'96 Chevy.

Chevrolet even used the same mounting location for the cable from '71 to '96.

The funky equalizer/adjuster.

Since the '94-'96 rear caliper hose is metric and the '73 axle hose is SAE English, needed a funky made stainless line made.

On one end a metric fitting with bubble flare.

And on the other good ol English 3/8-24 fitting with inverted flare.

It's just one long adapter really.

Routing of the line.

The Moser 9" did not come with the bump stop mounts on the axle so I replicated the originals off my old axle out of 4130 and used the original stops which cleaned up rather nicely.

Everything tacked in place, axle out of car for final welding.

Disassembly and paint.

Since the car had drum brakes in the rear and the original combination valve is just a rusty lump I bought a new combination valve for disc/disc. Now I do not trust anything aftermarket so I go through even brand new parts. Glad I did because the O-Rings used internally were so cheap they had loads of flashing from the parting line of the mold they were created on. This would have wept and more than likely made me cry.

Aside from the sub par O-rings the rest of the valve is nicely machined and made. I took apart the right hand portion and concluded it is a disc/disc valve. So really this combination valve does only two things. First is a basic shuttle valve to trip the brake warning lamp in case of one side hydraulic failure. The second job is a proportioning valve that only cuts in on panic stops. This limits hydraulic pressure to the rear brakes because under panic stops a good deal of weight transference takes place and lightens the load on the rear wheels and you don't need them skidding.

This brand new valve was only 40 dollars. Heck I'll use this valve on the old galaxies that are converted to dual master cylinders and add the brake warning lamp if not already installed as an option. I've looked at Ford shuttle valves and they easily eclipse 100 dollars.

I also started remaking the rest of the brakes lines out of stainless.

Next up are the caliper rebuilds. These are the fronts. Even though the brakes seemingly worked, one piston was so rusty it took 130 PSI of air pressure to get it out and it had to be replaced. Which is why you should flush brake fluid in all your cars every 5 or so years if you want trouble free long term service from them.

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