Originally Posted by
rsturbonutter
Mate he will defo need the master cylinder servo set up. You say that you are running four pots and that is why its fine on your car because you are only moving four small pistons as opposed to one large piston. The mondeo wouldn't have a bigger master/servo if a smaller would be sufficent would it. The size difference in the mondeo gear is quite apparent as they're a lot bigger than the xr3i standard piston. Its not rocket science to work out that if you need more fluid to move the piston then the pedal will travel further to acheive this. Then you got the fact he got discs on rear which again need more fluid than what is required to move the rear wheel cylinders. The mondeo gear is pretty straight forward to fit but a slight opening up of the area where it goes through the bulk head is required. Don't be put off by this as its only slightly. Hope this helps mate
I have had single piston 4x4 Cossie calipers on the front of my car too with a perfect pedal. The pedal was as good as it was previously with standard calipers.
How have you worked out that a set of large 4 pots will have need less fluid to move all the pistons than a large single pot caliper? My maths works it out as a smaller surface area for the fluid to work against and therefore requires less fluid to fill on a large single pot caliper than the known measurements for my AP 4 pots.
The pistons in my calipers are 41.3mm of which I have 4 of, and 38.1mm of which I also have 4 of.
The area of the 38mm pistons is 1140.09 x4 = 4560.36
The area of the 43mm pistons is 1452.20 x4 = 5808.8
Total surface area that the fluid has to work against = 10369.16.
The surface area of the single large piston caliper estimated at 80mm diameter piston works out as follows...
80mm piston area - 5026.54 x 2 = 10053.08.
I haven't bothered working out the rear calipers as both Normski and I are using the same calipers so would be a pointless exercise.