Did not give a Sunday update as we are still trying to get the brake system to where I feel comfortable.
Now you may ask, why the in-depth issue with the brakes, just fit them and get done.... well here goes..
Well there is an issue that is present in MeFusco, that is not an issue in VW single or double cabs.
The main problem is that in the VW you may have an empty load but you still have the motor and gear box out back,
This will in most cases prevent the back wheel dragging when brakes are applied, allowing a straight forward stop.
The MeFusco, has like zero weight on the back wheels and all the weight on the front,
so on braking, having disks all-round, the back wheels will lock up before the front has even started braking.
Should this happen it would be very easy to have the ass wip past the cab on braking.
This is where the proportional load sensing valve comes into play.
How it is supposed to work, is that the one half of the MC feeds the front brakes,
the 2nd half of the MC feeds the proportional valve inlet, and this is open to the feed back to the front wheels brake line linked to the 1st half of the MC,
The other port is to the back wheels. Now the valve is mainly closed to the back wheels when no load is on the back.
This brake fluid is directed to the front wheels as well giving twice as much pressure and volume allowing the front to do all or most of the braking.
When a full load is on the back, the valve opens fully to the back wheels and none is diverted to the front wheels,
In this case its as if the MC works like any other MC on most cars and VW with 1st half supplying the front and the 2nd half supplying the back.
So we could not get this stupid thing to work right and we where thinking we have the pipes incorrect.
Having tried all different ways we decided that as its new, it does not mean its perfect..... so
We went ahead and opened it.With all the parts laid out as they came out we could not work out how this could possibly work.
So finally decided to put my engineering hat on and re-assemble it the way I think it should be,
When done we tested it and Hey !! presto !!, it works......
It became clear that it must be a MONDAY assembled part as the spring was fitted in the incorrect place making it keep all ports closed.
So now to the final issue, as we have air bag suspension, the load will not regulate the ride height,
so the valve will not have a mechanical input to set the flow rate to the back wheels.
This we have overcome with a welded on set screw to set the percentage flow to the back wheels.
We may be able to find a happy setting for both full or empty loads, and per-set it there,
Or we will hand set it when load changes. this is only a few turns on a screw
OK so now you are up to date, and we can finalize the brakes this weekend.
Thanks for looking.
Herman