I'm new to automotive customizing and the aluminum threaded cover for my original Lotus Europa brake master cylinder sovy device is no longer available. From years of pauper existence, I have've had to hack what's broken, usually to positive results.This is no different.
The original design is as simple as they get. A cork, attached to a rod with a metal washer attached to it, floats in the brake fluid reservoir. As the fluid level drops, the cork drops as well. When the washer gets low enough, it comes to rest on 2 contacts, closing the warning light circuit... Simple.
Unscrew the heavy billet aluminum piece from your plastic brake fluid tank and let's get started.
Step 1: What You'll Need
The first thing you'll need to find is a cover that fit's the original billet aluminum housing. Plastic is a much better choice than the original aluminum. As you can see, the original cover portion of the unit on my car lost the electrolysis battle. A plastic replacement will be less bothersome in the future. I used the cover from a spice bottle.
You'll also need four #6x 3/8" sheet metal screws.
If your car is stock, and you want to keep it that way,. If your car is concourse, you'll have to find an aluminum screw-on cap.You'll also want to eliminate the screws and clean up or replace the original hardware.
Grab a screw driver, sharp knife and/or Dremel tool, various cleaning materials and we're off to the races.
Step 2: Pry the Part Apart
The original plastic parts of the sovy switch were held together with threaded rivets. These are easy to remove by prying the upper and lower plastic part apart. This switch has virtually no delicate parts or springs that can fly off or get lost if you do this. The rivets will simply back out of the lower plastic portion and the parts will separate. On mine, the float stabilization rod had rusted to the plastic cover, so I had to gently twist it with a pair of pliers until it broke free.
You can toss the rivets, but save the contacts.