Formerly unobtainable:

The 4 tab locks for the 1/4” nuts on the OD piston bridges were on the list till I found them at an aviation hardware supplier.

Still unobtainable:
The brass mesh filter in the bottom of the cast iron brake master cylinder reservoir, this I will be setting out shortly to fabricate.

All great ideas, thanks.

I've now got some 0.08mm Aperture - 0.13mm Wire Diameter 120 Brass Mesh and shaped it using a hole drilled in steel and the end of a drill bit with the edges softened.

I think I can use a copper washer turned down to the diameter of the original to solder the little basket to and press into the recess in the cast iron resevoir.

Graham;

That's the filter-screen I thought you were speaking of...I've never had much doings with it, other than to note it in position and wonder how important it really is (I'm pretty careful not to pour anything but clean, fresh brake fluid [now DOT5] in there), but I suppose it's presence is justifiable as a last line of defense against any debris getting ingested and damaging the piston seal...

...and now that you've removed it, I must ask the questions: How is it held there?...simply interference in the counterbored pocket?

In any case, it looks like you have a very good start making up a replacement...please document the rest of the work well...

Cheers

Ron, yes it’s just a press fit, I was surprised how easily the original came out with a haemostat clamped to the lip. Now the challenge is turning down the copper washers outer diameter, I’m thinking of a long machine screw and a nut to clamp it from spinning and provide a mandrel to put in a chuck to turn it while using a file. After soldering the new mesh basket in place then either using a 1/4” drive socket on an extension or a length of pipe to hold the part and press it in place.

Does anyone know what the reproduction version of this same master cylinder uses for a filter or if they have one?

We sell 2 versions of the brake master and both are aftermarket.

The economy version costs $80.00 and doesn't come with a cap and there isn't a screen inside the reservoir and I don't know who makes it.

The other costs $150.00 and comes with a new cap and has a metal filter screen inside the reservoir and is made by FTE and I believe they are made in Germany.
--
Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com

FAB made mine, which is probably original, I will see if FTE may sell a replacement screen.

Aren't they normally ATE?

I was mistaken, FAB is the maker of the rubber boot over the plunger.
I can’t make out any name on the body, just a number, S353 and Schafer on the filler cap

Schaffer was the original manufacturer for the single circuit brake masters used on 122 and 1800 Volvos.

From what I understand, FTE buys the molds/tooling to make some of their master cylinders from the original manufacturer. We've used and sold other FTE brake master cylinders for other Volvo models and never had a problem.
--
Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com

Graham;

...following with interest!

I would say if the copper washer fits just right, the trick is unifying the screen with it in such a way that it does not increase the OD...

Cheers

The plan is to solder the screen basket to the inner diameter of the copper washer, that way it will press fit copper to cast iron, leave a flat edge to press in with a tube like tool and ideally not add any thickness to the backside.

I’ll post when/if I have a result.

Graham;

To secure hardware, "drilling and safety-wiring" is always an alternative which can be used on just about any fastener...I do that now after witnessing the self-loosening of a Camnut shortly after first-start...I don't EVER want to hear those noises on a first-start again!

For the screen, as Greg notes...a simple fine screen, of brass or copper, can be made to the required size, then soldered to hold its shape...I have done this successfully also to make a prescreen for fuel...

If you give the size required, I can supply you with some of the superfine ⏜ wires per inch] solderable copper screen material (this is typically used as a pre-screen, for example as in the 1800ES tanks...any particles small enough to get through will be caught by an even finer paper post-filter)...otherwise if you contact me directly per e-mail with some more precise dimensions, I could make up what you need...

Cheers and Merry Christmas!

and the recess in the resevoir

This is the original and copper washer

What size is the brass mesh piece ?

If they are disks I have a hole punch for sheet metal (think a super duty paper punch) that will holes / disks to 9/32" diameter. Any sheet metal shop (HVAC) should have something like that.

TWP Inc will sell you a 3" X 3" sample of fine mesh screen for $10. They have ... 40, 50, 60, 80 and 100 mesh available.
https://www.twpinc.com/wire-mesh-material/brass

If you only need a small piece of brass mesh ( I have not counted the wires per inch), the sediment bowl gasket for a Ford 8N tractor comes with a piece of brass mesh for $3.
https://www.yesterdaystractors.com/Ford-8N_Fuel-Sediment-Screen-and-Gasket_2NAA916061.html

Greg