(HELP!) Rebuilding Cast Aluminum Jamar CB2 Cutter Brake

[ct937]

Hi guys, I'm looking to rebuild or replace my old Jamar cutting brake. It is the old school cast aluminum two handle unit with the pistons in the upright position. No modern units I have found will fit without significant modifications so at this point I am not considering using them unless they also have upright cylinders. Just trust me that I've tried, measured, cursed, bled, measured again, and cursed some more.

So after I got all that frustration out of my system, I went out and spoke to everybody I could about rebuilding this kit. This included the local off road VW shops as well as a run to Dune Buggy Warehouse and still come up empty. The internet has not been much better. I found a Kar Tek listing for a rebuild kit but it is NOT the correct rebuild kit for my unit. Same with Moore Parts. Check out the photos of my CB2's pistons and compare to theirs if you don't believe me. There are other sites that stock the same incorrect for my application parts. I was told mine was an early version(?)

Bore sizes are 1/2" as far as I can tell. The plunger measures into the .480's, the cylinder .490's, and the o-ring about .520.

I need help because this is the ONLY thing holding me up and it's been weeks of "nope, that won't fit, nope that won't either..." and I've come to the conclusion that I need to find a NOS Jamar CB2 or rebuild the one that I have. If I can't do that then I'm SOL shy of building my own completely custom unit.

So where does one BUY a NOS/rebuild Jamar CB2? Or where does one find the correct rebuild kit? Because every other unit I've seen online uses a different plunger and two springs per side. Mine does not.

Kar Tek, Moore Parts, among others stock these:

jamar-performance-cbrc-cast-aluminum-steering-brake-rebuild-kit_800x600.jpg

My parts look like this:

IMG_1156.jpeg

IMG_1157.jpeg

[CentralWAbaja]

You most likely are SOL. Try sourcing the rubber parts somewhere like https://www.mcmaster.com/ or least them as a starting point. there are the cable controls guys out there that might be able to help with the dust boots or a source for that stuff also. Maybe Jmar can help by telling you where they source the ones for todays kits?

[ct937]

I figured I was SOL. I just put a “T” junction in there for now.

I’ll try to clean up and rebuild what I have to the best of my ability. The biggest problem I face in that regard is figuring out what I need to replace the messed up looking black seal on the end of the piston. The two o rings were in darn good shape for their age. The newer style dust boots in the rebuild kits should work fine.

[risk]

That cup seal is basically the same as a hydraulic cyl cup seal.

Might try this?

https://www.theoringstore.com/index.php ... &cPath=371