Custom Master Cylinder, Pedal Box and Hydraulics

Master Cylinders/Pedal Box

We had been using the original tandem master cylinder originally designed for the bugeye; however, it was a master cylinder sourced from Gerard Chateauvieux of Gerard’s Garage that was modified to incorporate 3/4″ bore pistons for the brakes and the clutch.

Twin Chamber 3/4″ Master Cylinder

Sebring Sprites used a custom pedal box with two offset Girling master cylinders with their own fluid reservoirs. We purchased a replica of the Sebring Pedal Box from Brookfab in the U.K. https://brookfab.co.uk/

We were quite pleased with the Brookfab assembly including the master cylinders, push rods and springs – very professional job.

Brookfab Pedal Box with Girling Master Cylinders

Brookfab Pedal Box

Brake Pipes and Hoses

All new cunifer copper alloy brake pipes with stainless fittings were formed and installed on the car for the 2024 restoration. In addition, Goodridge Stainless Braided (black) were also installed on the car. Both can be seen in the image below:

Cunifer Brake Pipes and New Fittings

Cunifer Brake Pipes and Goodridge Hoses

Brake Fluid

We have decided that because all of the brake system and clutch system are totally new we will use Dot 5 silicone brake fluid in the Bugeye.

Front Disc Brake Conversion

We bought the Bugeye in 1998 and shortly thereafter the car was taken to Grand Touring Classics, Inc in Stanarsville, VA for a safety inspection and a conversion to front disc brakes. Garland Gentry and his assistant took care of collecting the needed parts from a post 1964 Midget and installing them on the car. After some period of time we changed out the 7/8″ master cylinder for a 3/4″ which worked much better.

Of course, it is not as simple as just switching out the brakes. it is also necessary to install new stub axles and king pins, dust tubes and springs, hubs, back plates, calipers, hose brackets, rotors, pads with pad retaining plates with clips, new hoses with banjo bolts and copper washers. For the complete restoration of the car in 2024 all of the front brake components were updated and/or replaced. Parts were sourced from A.H. Spares and Moss Motors.

The front brakes, steering and suspension are integrated in assembly. Details of all of these  mechanicals are detailed in other posts regarding these subjects. The build up of the front hub assemblies and brakes ,may be found in this post: https://valvechatter.com/?p=13792   A video showing the assembly is included in the post.

Rear Drum Brake Upgrade

A common upgrade to the braking system for Bugeyes is the replacement of the rear  drum brakes which use a single action 7/8″ rear cylinder with later MG Midget rear brakes using a larger 3/4″ dual action rear cylinder. We were able to acquire the later backing plates, wheel cylinders, and brake shoes with springs, and handbrake levers from Gerard Chateauvieux of Gerard’s Garage. He indicated that the donor car was in the 1968-72 time frame.

Rear Brake Components

LH Rear Brake Assembly with Shoes and Cylinder

LH Rear brake assembly

The conversion also required using new crossbars or rods for the handbrake system as the original Bugeye crossbars are not shaped properly for the later brakes. These were purchased from Mini-Mania.

Adjustable Handbrake Crossbars

We did have problems with the drums rubbing against the backplates and had to grind away some material from the hub edge to avoid the conflict. 

More information about the build-up of the rear brake conversion including an assembly video that details the problems we encountered may be found in two other posts: “Rear Drum Brake Upgrade”  https://valvechatter.com/?p=13399 and “Bugeye Rear Axle Assembly” https://valvechatter.com/?p=13569 in the restoration series. These posts and their included videos show the mounting of the rear hubs and brake assemblies to the rear axle.

Redundant Electric Fuel Pumps

The Bugeye began life with a 948 cc four cylinder motor that had a mechanical fuel pump mounted to the engine block. We converted to an electronic SU negative ground 12 volt fuel pump years ago and it was mounted in the engine bay. Then we mounted the pump in the rear of the car as outlined in an earlier post: https://valvechatter.com/?p=13599

SU electronic fuel pump negative earth

The SU pump was sourced from AH Spares in the UK. After acquiring the Michigan body shell we decided to modify the fuel delivery system yet again to incorporate a redundant electronic pump to have a ready back up in the case of a pump failure. The back up pump was sourced from Pegasus Racing and it is a Facet Cylindrical pump rated at 2.75-4 psi.

Facet Cylindrical 2.75-4 PSI Negative earth electronic fuel pump

The two pumps are installed in series and will be wired with a toggle switch permitting the selection of either pump or no pump at all – an effective theft deterrent. Nut serts (1/4″-20) were installed in the rear bulkhead to serve as mounting points for the rubber isolators, also purchased from Pegasus, that fit between the bulkhead and the pumps. 

A new stainless steel pre-bent fuel pipe was purchased from Summit Racing, modified to accommodate the new pump setup and installed in the car.

Bugeye Interior Personalizations

We have introduced a number of modifications in the interior to suit our interests. These are listed in no particular order below:

Gauges – Speedometer and Tachometer

The right hand drive connector for the speedometer cable on the Rivergate five speed conversion never worked well. Once the cable came loose and a second time the cable broke.

Rivergate Speedo Cable Adapter

Now seemed to be the perfect time to convert to the GPS speedometer sold by Bugeye Guy.

The unit is made by Speedhut instruments and apparently David at Bugeyeguy.com has a custom face made for the unit to look similar to the original Sprite gauge face. Details about installation including the wiring may be found in another post “A New Electrical System.”: https://valvechatter.com/?p=13986

The speedometer uses a gps sensor which routed between the driver’s door and the dash trim and is secured to the top of the dash with a magnetized plate.

Bugeye Guy GPS Speedometer

Bugeye Guy Speedo GPS Sensor

We liked the speedometer so much that we ordered the matching tachometer too!

Speedhut tachometer

Many of the electrical connections for the tachometer take advantage of the wiring loom provided with the speedo so that the tachometer can piggy-back for shorter wiring runs. Really happy with both of these upgrades. At first glance, the new instruments do look very much like the originals.

Hazard Switch and Lights

Of course, the Bugeye did not come equipped with hazard or caution lights. However, in today’s world and particularly with such a small car, hazard lights are really essential. The Classic Technologies relay/fuse box incorporates a hazard flasher relay system. We purchased a Lucas 155SA hazard switch to activate the system.

Lucas Hazard Switch

The switch is a push/pull type and incorporates a flashing warning light in the body of the switch. The switch will be added to the dash panel we built and is installed behind the dash.

The Lucas 155SA hazard switch was used in many British cars, and apparently the one we ordered was used in the 1974-75 triumph TR6 and the 1973-77 Triumph Spitfire. Details about installation including the wiring may be found in another post “A New Electrical System.”: https://valvechatter.com/?p=13986

Variable Speed Wiper Controller

Some years ago Ed Esslinger authored an article on a Sunbeam Tiger web site about a kit he put together to provide unlimited variable control of the speed of the Lucas wiper motor. We tried one of his kits on the Big Healey and liked it. Great for handling mist and light rain. Unfortunately it doesn’t make the wipers go any faster! 

We installed the control knob for the variable speed rheostat on the vertical panel we made and installed behind the dash. We took advantage of the blanking bolt nuts intended for the steering column bracket in a RH drive car as a location for mounting the  controller electronics. No holes were drilled in the chassis. Details about installation including the wiring may be found in another post “A New Electrical System.”: https://valvechatter.com/?p=13986

LED interior gauge lamps

All of the lights were converted from the original incandescent bulbs to LEDs sourced from Moss Motors.

LED Interior footwell and boot courtesy lights

LED interior footwell, map and boot courtesy lights operate remotely by a key fob or manually with a toggle switch on the panel behind the dash.  We ordered the RF Relay and key fob from Amazon. DieseRC 433Mhz Universal Wireless Remote Control Switch DC 12V 1CH RF Relay Receiver Module with 1 Transmitter, EV1527 Learning Code Remote Switch. Details about installation including the wiring may be found in another post “A New Electrical System.”: https://valvechatter.com/?p=13986

RF Courtesy Light Controller

The boot has two aimable LED lights. Each one is mounted on the LH and RH rear interior quarter panels. These lights were sourced from SuperBright LEDS. 

Boot LED Light

 

In the front footwells we also installed LED lights sourced from Better Car Lighting in the UK. 

Footwell Lights and Brackets

Turn Indicator Warning Buzzer

The turn indicator switch in the Bugeye is not self-canceling. While there is a warning lamp on the dash located between the speedometer and the tachometer, it is often not sufficiently bright to let the driver know to turn the switch to the off position. We installed a little buzzer sourced from Radio Shack to provide an audible alert when the flashers are turned on. 

Modified Windscreen Washer Pump (plunger) 

The Bugeye came equipped with a windscreen washer system that was activated by pushing a plunger mounted in the dash. The pressure created by pushing the plunger moved the cleaning fluid out to the windscreen. The process worked well enough, but when the Big Healey was restored we became aware of Stu Brennan, an owner of a Sunbeam Tiger, who had converted his hand activated pump windscreen washer to an electric washer. Stu’s idea was to put an electric momentary micro switch inside the aluminum pump canister thereby eliminating the need to install an additional switch somewhere. Since the washer in the Tiger is the same as the one in both the Big Healey and the Bugeye we decided to give it a try.

Two items needed to be purchased for the conversion. An electric pump typically used on later Sprites was ordered from Moss Motors.  A Home Depot switch was purchased, Gardner-Bender, Push Button, GSW-22, SPST always-off. Details about installation including the wiring may be found in another post “A New Electrical System.”: https://valvechatter.com/?p=13986

Washer Pump Parts

Under Dash Parcel Tray

Later Sprites and MG Midgets had a parcel shelf mounted under the dash on the passenger side of the car. We decided that it might make sense to add one to the Bugeye as well because there just isn’t much space for storing small items. The shelf was originally made from some type of fiberboard. We located a fellow in the U.K. who makes the shelves out of aluminum and for an extra commission will add the front rubber cushion to the shelf too. All at a very reasonable price.https://www.ebay.com/sch/i.html?item=116168223491&rt=nc&_trksid=p4429486.m3561.l161211&_ssn=bicycle55cps

This is an image of the shelf sans the rubber cushion. All of the mounting holes are incorporated. We will cover the shelf in red vinyl to match the interior.

Aluminum Parcel Shelf

 

Seat Belt Harnesses

Upgrading to shoulder harnesses was a must, but unlike the belts we had in the car previously, we decided on retractable units this time around. We ordered our belts from BugeyeGuys.

Red Retractable Seat Belts

While we generally try to do everything we can to avoid drilling new holes in the Bugeye sheet metal, it is required for this installation. Four holes in the interior floor and two holes in the rear wheel wells.

Seat belt mounting holes

Shoulder Harness Retractor Holes

 

This is a brief video showing the installed belts:

https://vimeo.com/942791115/4a83c628a8?share=copy

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