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Old 05/23/2012, 02:12 AM   #1
Dj Technick
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Default Custom made hydraulic handbrake

Recently I've been looking into doing a hydro handbrake setup in my 240, so I did some looking around to decide what I wanted and decided I was going to mount it inside the center dash (where the cd player goes). Powered By Max had exactly what I needed but they were out of stock. About a month went by and after sending them an email they were still out of stock and would be for a month! Tired of waiting I decided that I can make one myself! Looked up what master cylinder I needed and went to work.

I went with the Wilwood .75 master cylinder which will be used for a pass through setup. (part # 260-6089)


From there it was time to start designing how it was going to made.



Now that I had my design setup it was time to get to work. I took the drawings and headed on over to Hickman Racing. I've had Jim there help me out with a few projects before and he does outstanding work if you ask me. I showed up with the drawings initially planning on welding 5 pieces of medal together and drilling out some holes, just like I had setup in my drawings. However, Jim being Jim wanted to make this thing as badass as possible by making it from aluminum and throwing it in the CNC. Since that isn't exactly the cheapest thing to do we worked out a deal where I did some drawings for a part he was working on for a customer.

We scratched out the drawings I had initially done, kept the dimensions from it and gave the design a makeover. Unfortunately this was drawn up on the computer there and I never did a print screen of the file so I don't have a picture to show you all for that.

Cut out a chunk of aluminum to start with.



Threw it in the CNC





And out came this.



Next it was time to cut out a slot for the handle to slip into and drill out the holes for the master cylinder. From here out instead of using the big kid CNC we threw it on the small CNC mill and did the rest manually.



Test fit the master cylinder, also got a rod of aluminum ready for the handle.



From there went out and bought a shoulder bolt for the handle to pivot on, this way instead of it pivoting on the threads of a bolt it would have a nice snug fit and pivot on a smooth surface. This making the handle fit more tight and snug plus reduce wear and tear. Went ahead and drilled out the mounting hole for the handle and drilled out the mounting holes for the assembly itself.





Also bought a yoke for the master cylinder to connect to the handle.



Time to mill down the sides of the handle to fit into the slot made for it earlier, also had to mill down some more on the end for it to fit into the yoke.



Drilled the holes in the handle and did a test fit on everything.



As for the handle sizing I planned this out and went with a bmx handlebar diameter, this way I can throw a bmx grip on the end.



After looking this pictures over, I realized how crappy of photos they are since I took them with my phone. So here are a few pics taken with my slr showing each individual piece after completion and assemble. I'm still trying to decide if I want to paint the handle or polish it...hmmm...











There will be more pictures to come after installation.


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Old 05/23/2012, 06:20 AM   #2
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Default Re: Custom made hydraulic handbrake

this is awesome! nice work. I'm excited to see this installed.


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Old 05/23/2012, 10:23 AM   #3
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Default Re: Custom made hydraulic handbrake

Looks good Nick, I've been meaning to do the same thing.


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Old 05/23/2012, 10:55 AM   #4
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Default Re: Custom made hydraulic handbrake

Is it pushing or pulling on the cylinder? I would assume pushing but could be set-up for little play.


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Old 05/23/2012, 12:57 PM   #5
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Default Re: Custom made hydraulic handbrake

Hopefully I'll have it installed before next week. That all comes down to how much work this is gonna be.


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Old 05/23/2012, 03:49 PM   #6
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Default Re: Custom made hydraulic handbrake

Awesome work!


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Old 05/23/2012, 04:16 PM   #7
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Default Re: Custom made hydraulic handbrake

This looks pretty legit, impressive stuff. Is there a reason you didn't just get the ISIS or KSport one from enjuku?


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Old 05/23/2012, 09:59 PM   #8
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Default Re: Custom made hydraulic handbrake

I needed a forward facing one for where Im going to mount it, the only place that makes one like that is powered by max and they have been sold out for 2 months now and won't have any till mid June. Besides this was free to make.


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Old 05/23/2012, 11:40 PM   #9
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Default Re: Custom made hydraulic handbrake

Ahh, gotcha, I missed the whole forward facing part. Free also helps, not to mention the satisfaction of building it yourself.


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Old 05/24/2012, 09:28 AM   #10
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Default Re: Custom made hydraulic handbrake

So do the other ones have a spring to help release the pressure after you let go? If your pivot is it is smooth enough u might not need it i guess. But it would help to disengage. Just like a brake pedal or clutch. An how did you figure you would have enough leverage? With the pivot being so close to the other pivot point? But I guess the rod might be long enough.
I'm just wondering. I know I can come off as a ass but I am really wondering this.

Looks great. Very impressed nick.

Last edited by crxh22honda; 05/24/2012 at 10:25 AM.
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Old 05/24/2012, 11:28 AM   #11
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Default Re: Custom made hydraulic handbrake

Quote:
Originally Posted by crxh22honda View Post
So do the other ones have a spring to help release the pressure after you let go? If your pivot is it is smooth enough u might not need it i guess. But it would help to disengage. Just like a brake pedal or clutch. An how did you figure you would have enough leverage? With the pivot being so close to the other pivot point? But I guess the rod might be long enough.
I'm just wondering. I know I can come off as a ass but I am really wondering this.

Looks great. Very impressed nick.
No spring required, even now without fluid in it, it takes a little bit of a tug to get it to pull back. Think of it like your clutch pedal, that doesn't have a spring and the fluid pushes it back. Also the pivot is super crazy smooth beyond belief. As far as leverage goes, I made the hole to hole distance on the handle longer then the powered by max one is so my design provides more travel of the master cylinder which makes more braking force. I'm even going to go as far as saying that my design is superior. However I won't know that for sure until I use it.


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Old 05/24/2012, 12:44 PM   #12
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Default Re: Custom made hydraulic handbrake

More travel isnt always good though, you dont want to bottom out the piston.


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Old 05/24/2012, 01:32 PM   #13
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Default Re: Custom made hydraulic handbrake

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Originally Posted by Rosko View Post
More travel isnt always good though, you dont want to bottom out the piston.
I already checked on that and it doesn't go that far. It does come pretty close tho.


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Old 05/24/2012, 02:55 PM   #14
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Default Re: Custom made hydraulic handbrake

Quote:
Originally Posted by Dj Technick View Post
No spring required, even now without fluid in it, it takes a little bit of a tug to get it to pull back. Think of it like your clutch pedal, that doesn't have a spring and the fluid pushes it back. Also the pivot is super crazy smooth beyond belief. As far as leverage goes, I made the hole to hole distance on the handle longer then the powered by max one is so my design provides more travel of the master cylinder which makes more braking force. I'm even going to go as far as saying that my design is superior. However I won't know that for sure until I use it.


My clutch has a spring.....but yes that does sound pretty good u gotta let me check it out sometime. Very nice work.

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Old 05/25/2012, 01:26 AM   #15
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Default Re: Custom made hydraulic handbrake

Got it all mounted up today. Didn't take too long to do, had to cut out a little bit of plastic which is no big deal, and luckly I didn't have to take out the dash for drilling the holes.

I started by holding the assembly in place where I wanted it to mount, then cut out a piece of paper to size with the holes marked out on it. Its a nice easy way to make holes and have them be as close to exact as you can get.





Mounting it was kind of a bitch, mainly because there is hardly any room to get to the bolts. Getting my hand up in the tranny tunnel and around the trans was quite the task. It also took 2 people to do since one needed to be under the car while one was inside. Definitely worth it tho, fits beautifully and has plenty of clearance away from the shifter.



I should hopefully be getting the brake lines setup and this thing working by the weekend. It all comes down to if a local store has the fittings I need. The one fitting on the master cylinder is 7/16-20 thread finding an adapter to go from that to 3/8 or 10mm brake line isn't exactly the easiest thing to do. I might just end up doing stainless braided hose.


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Old 05/25/2012, 04:08 AM   #16
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Old 05/26/2012, 03:53 PM   #17
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Default Re: Custom made hydraulic handbrake

using the piece of paper to mark where to drill is genius. So simple but I never thought of it. Good work man.


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Old 05/26/2012, 04:01 PM   #18
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Default Re: Custom made hydraulic handbrake

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using the piece of paper to mark where to drill is genius. So simple but I never thought of it. Good work man.
Lol indeed it has been a tried and true way to get stuff right where you need it. Normally in the past I've gone as far as using my decal material to do the same. I just copy image on program, size it up and do a cut out and bbaamm.....instant template that won't move.


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Old 05/26/2012, 04:30 PM   #19
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Default Re: Custom made hydraulic handbrake




I'm kinda upset its not a samurai sword.

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Old 05/26/2012, 07:14 PM   #20
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Default Re: Custom made hydraulic handbrake

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Originally Posted by crxh22honda View Post



I'm kinda upset its not a samurai sword.
I'll probably do that later on down the road. I really want to do that still, just need to figure out how to make it work


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Old 06/03/2012, 11:32 AM   #21
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Default Re: Custom made hydraulic handbrake

Just got everything hooked up finally and fully operational. Took me a bit longer then expected, the master cylinder had a really odd ball thread pitch for the feed side (7/16-20 inverted flare) of course non of the parts stores had it, so I went to Thompsons and they didn't even have it. The only thing I could find is what wilwood makes and it goes from that thread to a -3 AN male. Then from there the only fitting I could find going from -3 AN to a 3/16 thread pitch (3/8 brake line) was also a male -3 AN. Which meant I had to buy a third fitting female to female -3 AN. Ordered them all from summit which here are the part numbers for all the fittings.

FRA-650303
FRA-496303
WIL-220-6410



Once all of that showed up, I got to work on the rest. Measured how much brake line I would need and bought the rest of the fittings I needed at the parts store. It was a breeze putting this all together, only took an hour to run all the lines, assemble it, and bleed the brakes. Here are a couple photos of the install.







I'm sure looking at all of that is a bit confusing so I modified the last image tracing the brake lines with colour and also drew up a diagram of how the lines run in the car.





Hopefully this should be self explanatory after looking at the pictures. Also one thing to note is the lines hook up after the proportioning valve, if you do it before it'll only make difficult to use the hydro brake.

Also here is a photo to show the clearance of the rod, my e brake is up and I'm also in first gear in this photo so you can see I'm not banging knuckles when shifting and I'm not going to come close to hitting anything when I pull the brake.



And last but not least here's a link to a quick clip testing the brake and showing that it works. It's not a crazy drift or anything so don't get your hopes up. Just me pulling a lever and the brakes locking.

http://youtu.be/8jTQ4XoNntc


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Old 06/03/2012, 01:29 PM   #22
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Default Re: Custom made hydraulic handbrake

I've got a ride in this beast with the hydro break. I must say some crazy shit. Even got my scared laugh going g lol. Very good work. Love it. I want a 240 so bad.

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Old 06/04/2012, 02:21 AM   #23
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Default Re: Custom made hydraulic handbrake

And to think Bobby said he wasnt going to build another car after the crx is done. but after riding in the 240 he wants one lol... Goes to show that once you build one car you cant help but keep building tell your dead! Road in this beast the hydro handbrake works amazingly compaired to his crappy old ebrake! Plus it adds style to his beast!

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Old 06/04/2012, 01:36 PM   #24
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Default Re: Custom made hydraulic handbrake

Nice work man, that must be one short throw shifter you've got there.

Now you need to come out with us one of these nights and let us see it in action.

If you can find the energy to change your wheels that is.

You lazy bastard.



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Old 06/04/2012, 07:05 PM   #25
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Default Re: Custom made hydraulic handbrake

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Nice work man, that must be one short throw shifter you've got there.

Now you need to come out with us one of these nights and let us see it in action.

If you can find the energy to change your wheels that is.

You lazy bastard.

Must harness my energy...Ah nevermind...too lazy.

I do plan on finishing off a set of tires before Sunday gets here. If you go out sliding any one of these days let me know.


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