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Originally Posted by saint123
Excuse my naivety but is that a must? How about flushing with 3 bottles of brake fluid?
Also I did not notice any noticeable dilation in the caliper rubber orings - if that has any significance at all...
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The problem is that there's contaminant in the system, now theoretically if you flush a ton of brake fluid through the system it should be okay. But, we don't know what was put into the system and if it combines or repels brake fluid; which means there could be nasty gunk still in the system.
The correct procedure is to replace anything that has rubber in the system with new components and then flush it with denatured alcohol to clean the metal lines. We've had to do this a couple of times on vehicles because customers put something other than brake fluid in the vehicle, it could be why your old master cylinder failed.
Though since you already built the front calipers (and hopefully the rears are okay, though it sounds like one is leaking for a different reason) you may want to just run denatured alcohol through it and then bleed it with fresh brake fluid. Worst case is that you'll have to replace the rear calipers and the rubber lines anyways.
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Is there any chance you may have used the wrong fluid at some point? When was the last time the vehicle had the brake fluid changed prior to this? Can you post a picture of the old master cylinder and the seals?