[dank]

Finally got some pics of my handbrake setup which a few people have asked for over the last year or two.

I was sick of the rear drum handbrake not being effective in Victorian conditions : mud, dirt, water, more mud combined with steep tracks makes for scary handbrake issues.

THe plan was to go rear disc brakes which I finally got around to doing this weekend so I needed a transfer handbrake that would hold on any angle as the idea was to use sierra front calipers on the rear which don't have a handbrake mechanism built in.

Materials:

KSI Mechanical Cable operated Go Cart brake caliper x 1 kit. - ~$125

5mm plate
2 x Cable knarps

4 ich grinder/plasma cutter/laser cutter etc etc
4 x 12.9 hex head bolts with spring washers and nuts (tailshaft bolts upgrade - 5mm longer)
25mm grade 8 bolts with correct thread for transfer mounting of caliper mount with spring washers.
1 x pit bike disc rotor with same PCD as tailshaft flange (hard to find but they are around - other option is to get any small rotor redrilled for correct PCD) ~$35.00

Ok pretty much what I did was mock up a cardboard template for the caliper mount and then used a 4" grinder to cut it to shape. You have to measure the relationship of the location of the pads to where the rotor sits. It just so happens that this caliper with 5mm mounting plate requires only a very small modification to fit perfectly onto the 4mm thick rotor i used along with the removeable shims to get the clearance of the caliper right. The spacer that spaces the top of the caliper out needs to be ground down by about 5mm. You will see this when you go to bolt the caliper up and the centreline between the pads is about 5mm too far away from the rotor.

Pics:



Sorry about the dirt, my zook gets used!

The KSI caliper comes with it's own cable. Use this an get rid of the OEM one. Run the cable up high out of the way and use the cable knarps to lock the end of the cable onto the handbrake mechanism. ALWAYS use at least two cable knarps or even better find a mate with a heavy duty crimper and crimp a lug onto the end. Good thing about the cable knarps is that they are adjustable. After 6 months I needed to adjust the cable to take the up slack from the initial stretch that develops in a new cable. Using two cable knarps means that there's no way for the cable to come loose as you have a backup. Use 3 if you are paranoid.

The only downfall to any tranny handbrake is if you have to stop in the unlikely event of having one wheel from each diff off the ground and no lockers. you will not stay where you are due to open differential action! So you need at least three wheels on the ground all of you hardcore zook wheel lifters!!!

Couple more things, you guys might notice I have lifted my transfer 50mm. I also have a 50mm bodylift. Clearance is good. If you have no bodylift you could still fit this with the transfer in the stock position. If you have a transfer lift and no bodylift you may struggle...but just find a smaller diameter rotor. I've never bashed my rotor. I think from memory it doesn't hang down much lower than the transfer case bottom.
Hope this helps yous guys out.

Total cost was around $175...taking into consideration all bolts, grinder discs etc etc. cheaper than a spidertrax kit and heaps more effective than a drum mounted handbrake...unless you like handbrake turns in 4 wheel drive...

Cheers

Dan
KPD4x4.com

[Rusho]

KPD4x4 transfer mounted handbrake kit Or at least a supplier for the calipers....can't find one for under $190

Good work by the way

[banga]

dont lotsa people use L series subaru calipers cause they are mechanical handbrake on them. the wrecker at beerwah has them for around $50

[Rusho]

banga wrote:

dont lotsa people use L series subaru calipers cause they are mechanical handbrake on them. the wrecker at beerwah has them for around $50

Where abouts in Beerwah?? Are they similar to the KSI item Banga?

[ball]

Rusho wrote:

KPD4x4 transfer mounted handbrake kit Or at least a supplier for the calipers....can't find one for under $190

Good work by the way

http://lightningkarts.com.au/index.php? ... uctType=71

[Rusho]

ball wrote:

Rusho wrote:

KPD4x4 transfer mounted handbrake kit Or at least a supplier for the calipers....can't find one for under $190

Good work by the way

http://lightningkarts.com.au/index.php? ... uctType=71

Thanks ball

[ball]

no worries

[banga]

Rusho wrote:

banga wrote:

dont lotsa people use L series subaru calipers cause they are mechanical handbrake on them. the wrecker at beerwah has them for around $50

Where abouts in Beerwah?? Are they similar to the KSI item Banga?

Yeah they have a mechanical lever on the side. i just remembered the guy who bought my old subaru is wrecking it prob get one cheaper than $50 let me know if your keen. 2 avaliable. no cables though jas got them.





these are a set i had but jas got them 2