
Originally Posted by
cygnus x-1
The MC leaking has nothing to do with everything else. If it's leaking there's something wrong with it, no matter what kind it is. So you need to get one that doesn't leak. If it's new, exchange it for another one.
As far as the brakes not working, since you've replaced nearly everything in the system I'm betting there is still air in the lines or calipers. It takes a LOT of bleeding to fill a totally dry system. You also MUST bleed the MC first, preferably off the car. If it has any air in it, the pedal will feel squishy and you may never get full braking power.
About the booster, I wouldn't bother replacing it unless there is something wrong with it (leaks, super rusty, etc.). The stock booster is fine with the rest of what you have.
For the size calipers you have you probably want a 15/16" MC. A 7/8" MC should also work but it may be on the small side, which means it will take more pedal travel. It will also be more sensitive to air in the lines.
I would not recommend eliminating the booster unless it's either a show car only, or you know EXACTLY what you're doing. It's possible to have a fully manual disc brake setup that stops well, but it has to be setup correctly for the car, which probably means changing the pedal ratio to make up for the assist you were getting from the booster. Even when setup correctly it will take more pedal effort to operate and it will feel different (more pedal travel) from a power assisted setup.
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