Brake Calipers

[markh15]

Hi Guys,
I've spent 2 days freezing  in the workshop, and I think I have it nailed!
I must admit that it has given me some problems, mainly because the calipers are the same hand, and not 'mirror image', which is what we need.
After a lot of head scratching, some welding, a bit of wasted metal and some swearing, I have it sorted.

This is a picture of the right side Caliper and Bracket


And this is the Left side

Notice the cranked bracket

they both sit in the right position, although the left caliper is technacally upside down.

The next shot is of the brake pedal


and the cable attachment points



I am going to pass the cable inners through the holes as they are, and not slot them, to stop the cables jumping out of place.

And finally the outside view of the caliper


Sorry about the quality, but I was trying to hold the bracket and the camera whilst lining up the shot, maybe the Boss should have designed Toylander builders with three hands!

After some consideration, I have decided to replace the 6-1/4 ins (160 mm) discs that are fitted at present, with 7 ins (180 mm) discs, to give me a little more room for the pads to contact the rotor, so I will drill the floor and bolt the brackets in place then, but I think you can all see how it will work.

I have more pictures, but I don't want to take up a lot of space, so I'll post the rest on my website, along with a couple of drawings, and dimentions just incase anyone wants to use them.

Keep busy,
Regards,
Mark.

[quadra]

Looks good Mark, how are you actuating the cables. The ones on our toylander are ok, but i think the pedal ratio needs to be better and could probably do with some sort of cam at the top of the pedal to help pull the cable, if that makes sense.

[markh15]

Hi Mike,
the arm on the caliper is a cam. The cable passes through a bracket on the caliper, and then clamps to the arm with a small nut and allen bolt. You can just make them out in the picture of the right caliper, the cable bracket is molded into the caliper, see picture below,
 


Rather than having the adjusters on the caliper, I'm going to have them on a bar on the bulkhead, where the cables pass through to the pedal. This way, they will stay clean and easy to adjust, while being away from little fingers.
The cables will run out of the bottom of the battery (engine) bay, and along under the car to the calipers. The route isn't definite yet, but everything is mounted for the smoothest route possible.
Forgot about the cable mount, good point, well spotted speedy!
Keep busy,
Regards,
Mark.
p.s. how about some pictures of yours in the gallery Mike?

[markh15]

Hi Brian,
I could teach you to MIG weld in about 10 minutes!
I'm self taught and it's only practice that makes you better!

The thicker the metal, the easier it is, the real art is to stick car body panels on without blowing holes!

I am not as good as some of my mates, but they tell me my welding is N.P.B.F.,
apparantly it stands for Not Pretty, But Functional!

As for the Stopping Distance,  Nearest Wall, ABS, in my workshop that stands for Anti Bulls**t System!!
I'll let you know when it's finished, but I'll be wearing a big pair of boots just incase!

Keep Smiling,
Regards,
Mark,

[multisync]

Hi Guys
Interesting what you say about welding. I have an arc welder, and thats what I use for everything, great for wrought iron gates and heavy stuff, I've built a couple of trailers, all OK, but much more dificult, if not impossible, for thinner metal. I had a MIG at one time but found it quite tricky, metal had to be extremely clean for one thing. My other problem is that each time I went to use it, I needed to have lots of practice first, to get a successful weld. Then when I come back to it weeks later, lots more wasted metal and gas, before I could achieve anything useful. I also found it expensive on gas. Whats the secret? I don't have it now, but would buy another one if I thought I could get anywhere.
Walter

[multisync]

Mark
Its all too late to tell you now but mini moto Brake Calipers are "handed", you might want o look at ebay item 150308091071 for future reference, doesnt mention the discs tho, only calipers.
but....
Walter

[markh15]

Hi Walter,
Thanks for that, I've had a look.

Maybe for a future 'Re-fit'. The only thing that bothers me, is that they might be a little too fierce for the car. The brake pads for the mini moto look a bit bigger than the cycle ones, and I fear they may grab, but I think they would suit a petrol driven car though, well spotted!

I'm trying to get the drawings for the brackets onto my website at the moment, but there's a problem somewhere, and it won't accept them. Maybe they're updating the site or working on it, will try again tomorrow.
Keep Busy,
regards,
Mark.