[Steve-o]

Hello,
I'm a 501c3 volunteer working on parade machines for a non-profit group.
We have installed a Peerless Gear differential in place of the original solid rear axle so the buggy can turn more better during parades, (its a future parade rig).
This required that we support both axles near the differential pig. We also had to provide braking to both axles, both stop and parking brake systems. So here is the rub, sorta speak. We added another hydraulic line to the master cylinder by using a double banjo bolt. The banjos were located accurately with suitable thickness washers. We bled all four calipers with limited success. The pedal is wonderful for the front calipers. Outstanding performance with only 1" of pedal travel. The rears, not so good at all. The caliper cylinders move 0.10-0.15" with no pad movement. The bleeders on the rears are lower than the banjo connection so we bled through the banjo bolt several times. To date, we have:
Determined that the machine maybe never had functioning rear brakes
Replaced the master cylinder thinking that the piston was jammed
Adjusted the pressure rods for more movement on the rear system.
Tried only one rear caliper at a time
Tried only one pressure rod in place on the pedal linkage to the master cylinder
Considered leaving the buggy with the rear-end elevated over-night
Considered removing the brake switch and using it as a banjo connection for the rear brake system
Considered adding a second master cylinder, one for the front, one for the rear
Yup, its a long story,
Thanks in advance for your time and thoughts,
Steve-o