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Thread: *HOW TO* Corsa brake servo setup

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    Senior User Iain's Avatar
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    Default *HOW TO* Corsa brake servo setup

    PARTS

    Take one complete Master cylinder/servo setup from a scrap Corsa. Also get the strengthning plate below it.



    FITTING

    Position the Corsa plate in the right position, you'll be looking roughly here in the battery tray:



    Holesaw or cut a square hole for the assembly to drop through roughly in the right position as so:





    You'll find the pedal is far too long, but don't worry yet:



    Weld in the tray when you know it's in the right position:



    I added drainage grooves and lots of seam sealer to stop water sitting:



    As for final mounting, I rotated the assembly to sit like this, as it cleared the scuttle and bonnet better:





    PEDAL

    Next you'll need to cut/shut the Corsa pedal. I used a Nova pedal:



    Welded to a Corsa one:



    And braced it both sides with thick plate:



    ADDITIONAL BRACING

    It's well worth bracing the assembly using an existing Nova pedal setup, as you may find the bulkhead flexes when depressing the pedal hard:



    All fitted:



    BRAKE LINES

    For brake lines, I was making up some custom lines, but consider using the Corsa 4 way distribution block on the bulkhead:


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    Did you just use the top port to run both front and the bottom port to run both rears?

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    Senior User Iain's Avatar
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    Yep. If you used the Corsa distribution block then you could do the proper diagonal split though (just means running 2 lines to the rear)

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    Go low or Go home. Moderator Benn's Avatar
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    Very handy. I fancy doing this, but was a bit worried about what needed doing under the dash. As i remember James (count vaux) doing alot more cutting and welding and bits.

    Thank you IaIn.
    All I wanted was a Pepsi, just one Pepsi
    Far from suicidal
    Still I get them tendencies
    Bringing back them memories
    That I really miss when I reminisce

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    That's a good guide. Have you got any kind if bias adjustment. It doesn't look to have any restrictor and is it also ok to use on a rear disc conversion.

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    Senior User Iain's Avatar
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    With a single line to the rear I have used a Wilwood in line bias valve. I've had this on for both drums and rear discs. Its recommended.

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    I just fitted a nova mc

    Good right up

    What did you do about supporting the clutch pedal?

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    Senior User Iain's Avatar
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    Cut down the main pivot rod, cut down a brake pedal, and weld it to the scuttle. At least that's what it looks like I did, don't really remember


  9. #9
    Go low or Go home. Moderator Benn's Avatar
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    Does the pivit bit not need to go in to the brake pedal casing like bit?
    That was one bit i was thinking would be a bit harder.
    All I wanted was a Pepsi, just one Pepsi
    Far from suicidal
    Still I get them tendencies
    Bringing back them memories
    That I really miss when I reminisce

  10. #10
    Senior User Iain's Avatar
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    Nope.

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