How to waste about 20+ hours of time and be in a worse position then when you started.....
The car has been running fine, very well in fact. The only major issue I had was the brake lights intermittently sticking on. The easy options would have been to wire up a new switch, or replace the original. perfect time to upgrade the master cylinder to an AVP kangoo MC and braided lines all round that has a new brake switch included

whilst there I wanted to replace the steering joint.
First up was to drain the fluid then remove all the old hardlines and MC setup. bit fiddly but not too hard to do, just time consuming on your back. Once that was out of the way I was then able to disconnect the steering column and remove the rack. Angle ground off the original fixing and replaced with a sub standard piece of chod! I've genuinely had tougher souls on my shoes than this feels.... any way, the old one was destroyed so it'll have to do for now, even though the column now has some flex up and down 🤷♂️ frustrated so added a reinforced replacement to my basket and refitted the rack, that's about 5 hours work for me
Next up was to fit up the new MC and adapter, tight squeeze but again not too bad. braided lines laid in place and connected up to the already braided flexis to the calipers, rear was a pain to do, mainly for the removal of the compensator valve. Once I had swore at it a few times I was able to replace it with a T piece and connect up the rear of the car. I then mounted 2 new reservoirs to feed each side of the MC. Topped off the fluid and started with a few rounds of pressure bleeding. Everything came through nicely so I thought I was onto a winner. Concludes another 5.5 hours.
The next job was to get the MC rod setup. There are a few lengths available and they are also adjustable. This needs setting somewhere close to .5mm according to the manual, but basically close with a slight gap so that the MC can be completely disengaged and the fluid can go through the return port. Got this done and went to give things a try. Flexed the brake pedal from underneath but got next to no movement on the front caliper. Did this a fair few times, assumed id not got the rod set correctly or bled it properly. A few more times on both making sure I was happy and still got the same result... 🤦♂️ found it I stomped on the pedal to the bottom of its stroke I could get some pressure at the caliper but did note that when pumping it never built anything up. Dropped the car on all 4 wheels and gave it a test drive hoping that it just needed some "use" this was not what it needed... also found that the throttle cable had gained length, likely due to me changing its routing slightly under the car then laying in the new brake line. The end then needed some angle grinder action to get it to the right length to remove the floppy pedal and get full opening at the carb. Anyway, pushed the pedal so far that i knocked the MC feed pipes and adapters out! Made a big mess on the drive as I didn't realise 6.5hrs
A bit of reading and some back and forth with good old chat gpt, it suggested a few things, the MC wasn't bled properly and could need doing on the bench, it was a complete miss matched part (though its sold as an upgrade and others use it) or the MC was faulty.
Decided to give bench bleeding a shot, removed the MC and the adapter after draining all the fluid again. Have never done this so didn't know what I was looking for or feeling for, it actually took a fair amount of fluid internally and "moved" fluid around so set back on refitting it all. Followed by multiple rounds of pressure bleeding and rod setting. guess what.... still the same issue. Even if I over set the rod I still didn't get force enough to stop me spinning the discs by hand or with a bar. Starting to lean towards a failed MC now.... Took the front calipers off the discs to see if I could build pressure and move the pistons, expecting them to pop out quite quickly, got next to no movement. Now I was starting to question myself, how well it braked previously and if the front pistons had seized (thinking back id still expect to build up some pressure in the pedal wouldn't I?) so next I whipped off the calipers, boots and checked for corrosion, looked clean and I could lever the piston forward a few mm and then compressed them back easy enough, slapped back on and now I have walked away. Probably another 4.5 hours there
So now I have an immobile car, with no working brakes, and worse steering than it already had and I'm meant to be driving it to Goodwood for Retro Rides in 2 weeks. All I want to do is burn the thing. I should have got onto a lot of this sooner but have now ordered up a new MC which should be here early next week and just for good measure the steering joint (could possibly get one made from solid ali?), yet more brake fluid and 2 new front calipers and new pads, just because. Will any of it be here in time, I doubt it...... To make it worse I've been sick as a dog the last week so haven't been thinking about it much, should have got onto ordering a week ago but genuinely thought I had a month or so to go till Goodwood 🤦♂️