There are a few reasons why you would want or need a new master cylinder cover. Some reasons are strictly aesthetic, and some are to overcome issues – like leaks.

In our case, we’re creating a new cover for both aesthetics and practicality.  Our original cover (shown above), which came with an otherwise quality master cylinder, is a cast piece. It’s way too thin and it warped, which led to leaks. We tried a few things to fix the leaks, but they kept coming back.

So we started with a block of 6060 aluminum. First, we squared it up on the mill. Then we brought the block dimensions within tolerance.

For the purpose of this article, we coated the block with layout ink and scribed the desired design. We began oversize with ¼” walls, which after testing we brought down to just under 1/8”. In the above pictures, you can see how we milled out the pockets, and then drilled the center mount hole.

After some fine cleanup with the mill, we installed the cover on the master cylinder and took the car out for a spirited drive to make certain there were no leaks.

With the leak issue solved, we decided to make the cover more compact. We copied the design of the valve covers to tie the engine compartment together.

We fixed the leaks and dressed up the engine at the same time. It saved us the frustration and cost of having to change out an otherwise good master cylinder, which would have caused us to fabricate new brake lines.

In our experience, it’s often better to work with what you have than just to throw money at a problem.

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With over 40 years of combined restoration experience, Capp’s Hot Rods rebuilds and restores Model As, Deuces, ’33s and up, classic cars of all makes and models, and muscle cars.  Located in Woodland Hills, California, Capp’s specializes in complete wiring services, from repairs to complete harness installations.  Visit their website or call 818-974-7530 for more information… or to schedule an appointment for your classic car.  You can also find the Capp’s team at the Pomona Swap Meet on Road 22, Spaces 22, 24 and 26.