Mk III Parking Brake Relocation How-To

[dv/dt]

The enclosure was formed out of a single piece of 0.040" 6061-T6 Aluminium.

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod1.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod2.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod3.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod4.jpg

[dv/dt]

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod5.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod6.jpg

Mocked up the transmission to check for clearances. It is in first gear and there is plenty of room with the brake down.

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod7.jpg

Also, lots of clearance with the trans in 1st and the brake handle all the way up.

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod8.jpg

[dv/dt]

About 1/2" of clearance between the transmission and the enclosure with the transmission cover sitting slightly ahead of it. Plenty of clearance since the transmission will not move fore/aft due to loading. The front lower corner could be trimed and then closed up to give more clearance if required.

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod9.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod10.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod11.jpg

The mount was made up from a piece of 3/4" X 1-1/2" tube.

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod12.jpg

[dv/dt]

Enclosure mounts under the handle mount.

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod13.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod14.jpg

I still have to weld in a mount for the cables but that will be the same as the existing mount on the passenger side. Once that's done I will be able to determine exactly where the cable will exit the enclosure. The cables will be shortened to fit by swaging on new ends (found a hydraulic shop that can do that). There is plenty of room to run any wiring under the enclosure.

I have to get myself a metal brake one of these days!

[dv/dt]

Pics of the dash clearance:

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod15.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod16.jpg

And some pics of the enclosure out of the car:

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod17.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod18.jpg

[dv/dt]

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod19.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod20.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod21.jpg

[dv/dt]

Here are some updated pics of my parking brake mod. Almost complete except I still have to fabricate the access hole cover. Even used the leather boot that comes with the kit (modified). Need to put something on the handle to hold the boot tight against the handle. Had to make a new T-cable about 3" longer and shorten both rear cables.

Let me know what you think. I'm extremely happy with the way it's coming out.

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod22.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod23.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod24.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod25.jpg

[dv/dt]

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod26.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod29.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod28.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrakeMod27.jpg

[dv/dt]

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrake-MountingBracket1.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrake-CableBracket.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrake-CableBracket1.jpg

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrake-CableBracket2.jpg

[dv/dt]

http://img.photobucket.com/albums/v668/dvdt/Brakes/ParkingBrake-CableBracket3.jpg

Here's a copy of the bezel drawing. It was made from a piece of 4" x 1/8" 6061-T6. I got a 42" piece for about $12 CDN.

http://img.photobucket.com/albums/v668/dvdt/Brakes/BezelDrawing.jpg

Here is a drawing for the mount. I'll post them for the enclosure and cable bracket when I get a chance to draw them up.

http://img.photobucket.com/albums/v668/dvdt/Brakes/Mount.jpg

Here's the cable bracket.

http://img.photobucket.com/albums/v668/dvdt/Brakes/CableBracket.jpg

[dv/dt]

Finally, here is the drawing of the enclosure (which is optional).

Black lines = Cut lines
Magenta lines = Bend lines (note the legend in the lower corner. Bend them in the right order and direction)
Green lines = Mark and bend lines only after fitting to car
Brown/Red lines = Construction lines - do not cut or bend)

http://img.photobucket.com/albums/v668/dvdt/Brakes/Enclosure.jpg

[dv/dt]

Final product with custom billet handle and built in indicator light.

Parking brake off.

http://img.photobucket.com/albums/v668/dvdt/Brakes/PBLight1.jpg

Parking brake on.

http://img.photobucket.com/albums/v668/dvdt/Brakes/PBLight2.jpg

http://img.photobucket.com/albums/v668/dvdt/Dash/DashA1.jpg

Cheers, Rod

[mrmustang]

Rod,

That is an absolutely flawless application, I especially like the indicator light built into the button head.



Bill S.

[FFinisher]

Wow, now that is a nice Job, One of the cleanest e-brake Mods I have seen, Nice work!

[dv/dt]

Rod,

That is an absolutely flawless application, I especially like the indicator light built into the button head.

Bill S.

LOL Bill, I was forced to have a light by the safety inspection guys during my first inspection. The fact that the handle sticks up right in front of you didn't appease them.

Cheers, Rod

[mrmustang]

LOL Bill, I was forced to have a light by the safety inspection guys during my first inspection. The fact that the handle sticks up right in front of you didn't appease them.

Cheers, Rod

Innovations like yours are the driving force behind the FFR kit and community as a whole. That plus necessity is truly the mother of all inventions, keep up the great work.


Bill S.

[rich grsc]

Rod, glad to look over this again :) How necessary do you think the enclosure is? There is none used in the original location, and that looks to be the hardest thing to fab up.

[Jeff Collins]

Great idea ,and great detail. Thanks for sharing.

[NAGA]

Rod, glad to look over this again :) How necessary do you think the enclosure is? There is none used in the original location, and that looks to be the hardest thing to fab up.

If you don't live in the Great White North it's probably not as critical Rich! :)

Didn't Rod do a super job on this? I love fellow engineers. One of these days I'm going to get around to doing the Fiero handbrake mod on Naga. I'll take a shot at documenting it for everyone too, but dang, Rod's set the bar really high. I'll have to do mine in Catia.

d

[dv/dt]

Rod, glad to look over this again :) How necessary do you think the enclosure is? There is none used in the original location, and that looks to be the hardest thing to fab up.

It may have been overkill in hindsight. The only thing I don't know is what the air pressure would do to the leather boot without the enclosure. It's strong enough to lift my cup holders out of the trans cover at about 65 mph but the handle would be down so the boot shouldn't have anywhere to go.

Cheers, Rod

[fastlane82]

I had just thought of that not that long ago! I never liked the e-brake on the pass. side or just sitting on the trans tunnel, that does look quite nice. I personally would have the trim ring chromed, but it looks like it will go with your more brushed look. Oh and by the way this is my first post!!

[dv/dt]

If you don't live in the Great White North it's probably not as critical Rich! :)


d

LOL, yeah, it helps keep the snow from coming through!:)

[NC Jim]

That looks amazing, just like all your mods have.

[Jeff Kleiner]

Inspired by Rod I did the same only without the enclosure. No Ill effects in ~10,000 miles. I made a bezel and was able to use the FFR supplied boot.

http://i269.photobucket.com/albums/jj43/jkleiner/100_0930.jpg

It is one of my favorite and most useful mods.

Thanks Rod!

Jeff

[seagull81]

I hope all you talented guys bring your Mod links over from FFCars. I believe I'll be on this site more and more. Thanks, Rod.

[GWL]

Great post and great pictures. I had been studying Morgans as they have done it the same way.

I was thinking about this a while back but decided not to do it. You've got me back into again.

I'll be out in the shop tomorrow thinking this out.

George

[Kevin Davis]

Nice work!

Couple of questions:

1) Any reason to not just reuse (cut and re-weld) the frame components from the original location? I like your fabrication you did, just curious though.

2) Are you guys using cnc machines to make the bezels? That looks to be the hardest part.

[Cobradavid]

Beautiful job!

David

[JJ in Cbus]

I have to give dv/dt and JKleiner credit for the inspiration here. I wanted to move the eBrake handle to the top of the tunnel and I also wanted to use the parts I had on hand. Here is what I came up with. I used 2" x 1/8" angle iron and 1 1/4" x 1/8" bar stock to make my brackets.

My brackets hanging in my rattle can paint booth.
http://i118.photobucket.com/albums/o95/jjincbus/Cobra%20Build/EBrakeBrackets.jpg

http://i118.photobucket.com/albums/o95/jjincbus/Cobra%20Build/EBrakeFrontBrackets.jpg

The rear bracket is just a piece of bar stock drilled and bent in a vice to match the 3/4" bar angle and mounted with a grade 5 cap screw.
http://i118.photobucket.com/albums/o95/jjincbus/Cobra%20Build/EBrakeRearBracket.jpg

http://i118.photobucket.com/albums/o95/jjincbus/Cobra%20Build/EBrakeTop.jpg

jj

[dv/dt]

Nice work!

Couple of questions:

1) Any reason to not just reuse (cut and re-weld) the frame components from the original location? I like your fabrication you did, just curious though.

2) Are you guys using cnc machines to make the bezels? That looks to be the hardest part.

1) I never really looked at it but just of the top of my head I doubt it would work. The mount would have to weld in from the opposite side somehow and I did want it raised the 3/4" to position it where I wanted.

2) I made the first bezel (shown) by hand. It wasn't perfect (one slip of the handand ....) but pretty good. We recently had a water jet company cut out 2 for a buddy and I.

Thanks for the kind words guys!

Cheers, Rod