Because now we are installing a dual and completely independent brake system which separates the front from the back (unlike the OEM set up which runs diagonally and uses a single reservoir), we decided not to use the majority of the OEM brake lines. We ended up making new lines and passing them in totally different locations.
Rear brake set up.
Here's the right rear brake line and where it all starts. You can see the black OEM line to the right. Like I said we are not going to use it. It as been cut and removed totally front to rear. I also decided to get two new stainless steel lines made up for the rear brakes because the new Alcon calipers do not use the same size fittings as the OEM calipers. The new hard lines run towards the back and down initially and then back towards the centre of the car and then back upwards.
Same thing for the left rear brakes line. I am using the OEM bracket to secure it in place.
Now that both rear lines are running towards the centre and come back upwards they end up going through the trunk floor and then towards the middle of the car and a T union is used to connect both of them together for their run forward.
From the T union at the trunk level the line runs forward and down over the rear seat area and then turns 90 degree to the right (looking forward into the car).
From the right 90 degree turn it turns another 90 degree downwards and runs along the right side of the car along the tranny tunnel.
It runs all the way forward along the tranny tunnel to cross back to the left side by going over the tunnel behind the centre console and underneath the heater core area then down to the brake pedal.
Front brake lines and clutch line.
A round aluminium plate (~ 4 inches across) was made to seal the motor compartment and the inside of the car. It was drilled with the appropriate holes to allow the hoses and the one hard line to come across the firewall. You can see the front brake hard line coming through.
Now after coming through the firewall the hard line turns 90 degrees to the left and up and continues through the secondary firewall through a rubber lined hole (where the main ECU harness used to be) and butts through another T union where an hydraulic pressure switch is located (for brake light activation) and continues forward to another T union to split and butt with the left and right OEM brakes lines to the front calipers.
Here are the three brake fluid reservoirs. They are secure to the OEM stress bar. You can see the 3 gravity rubber feed lines.
Another angle/view of the reservoir area. Now you see that the hard line was wrapped in rubber tubing to protect it from metal to metal contact when going through the firewall plate. The three rubber hoses fit snugly through it and do not move. You can also see the stainless steel clutch line butting into the OEM hard line that goes down to the tranny.
The stainless steel clutch line. Approximately 20 inches in length and fitted with the appropriate fittings at both ends to mate with the master cylinder and the OEM hard line at each end.
Finally the pedals and all their lines hooked up to them.
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Originally Posted by Jet Jockey
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