AUSTIN MINI CLUTCH CYLINDER
Q
I have a 1962 Austin Mini and will shortly be embarking on the job of replacing the clutch master cylinder. This is a job I have done many years ago and remember the frustrating task of attempting to locate the cotter pin and then get the split pin in place. I always find this job a bit of a fiddle and was hoping that there may be an easier way, or at least a trick to make fitting it easier. I did once hear of using a piece of welding wire attached to guide it into place, but do not have the facilities to connect the welding wire to the cotter pin. James Gooden
A
The method you describe of attaching the welding rod can work to position the cotter pin, but this has the disadvantage of leaving the welding rod attached to it which then needs to be at least cut short to prevent it becoming a problem. The method I always use is to make a small and versatile tool from a length of kunifer brake pipe. Cutting the end of the brake pipe down the length, the two halves can then be moulded around the cotter pin. The brake pipe is malleable enough to press around and secure the cotter pin, but soft enough that once in place it can be pulled out of position and removed completely.