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Tutorial Diy Hydraulic Handbrake

Discussion in 'DIY peripherals' started by tombo, Jan 11, 2015.

  1. tombo

    tombo Active Member

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    Since i've ordered some parts for my Simulator which will take some time to arrive, i would like to build an Hydraulic Handbrake.

    I've seen this Thread while borwsing around the internet. http://www.isrtv.com/forums/topic/10762-dsd-hydraulic-handbrake-diy-project/

    Since i find any thread here about this I decided to build my own and make a little tutorial for all others who are interested.
    I did some research on the parts i'll need.

    First i bought a cheap cluch cylinder at ebay from a Mitsubishi Carsima DA II. It looks great, since the resevoir is included.

    [​IMG]

    It whas hard for me to find a pressure sensor for moderate price in Germany. The only one i found was at Dealextreme. But it has lower pressure ratings.
    http://www.dx.com/fr/p/carbon-steel...sensor-silver-black-dc-5v-343234#.VLKKpXtGQiA
    [​IMG]

    The sensor will output a 0-5V signal, perfect for the Usb Interface.


    The guy on the link above used a second cylinder with some dampers. It's called a slave cylinder. I didn't find any solution about this at the moment. But next week i'll talk to some people mybe they can help me.

    Since i hate stripping appart old gamepads and I'm to lazy to build my own circuit : )
    I'll use an Arduino as Joystick Interface. Also it has ability for buttons which I'll use too.

    More info about this can be found here https://code.google.com/p/unojoy/
    It's really easy to setup and i've done some testings with buttons and potentiometers and it works very good.
    Set by step instruction can be found here https://code.google.com/p/unojoy/wiki/GettingStarted

    The cylinder must be arrive in the next days so i can build a holder and lever for this.

    If you don't want to build it your self, there are many handbrakes aalible for a good price on ebay.
    http://www.ebay.de/itm/Hydraulische...le_ohne_Strassenzulassung&hash=item339ba9881d
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    Last edited: Jan 11, 2015
  2. Ads Master

    Ads Master

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  3. RacingMat

    RacingMat Well-Known Member Gold Contributor

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  4. tombo

    tombo Active Member

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    Hello,
    today the Clutch Cylinder from carisma arrived. After cleaning i try out some holders with cardboard at the moment.
    IMG_3443.jpg
    I did a lot of research on the pulling slave cylinder. Most people use this one.
    [​IMG]

    More Information here http://www.wilwood.com/mastercylinders/MasterCylinderList.aspx?group=Slave Cylinder
    This one looks perfect for adding some skateboard DOH DOH's to create some force to push against.
    But these are no common cylinders used in car industrie. More established in tuning and racing scene.
    For me in Germany i didn't find any pulling cylinders. The wilwood is avalibe but is over 100€.

    So i talked to some people at work using a pushing type slave cylinder. There are many avalible for cheap prices. But make shure you use one from an older car like this in the picture. They are out of metal and will be more robust. The newer ones are all plastic. The should handle the force without problems. Even a master break cylinder would be better.

    [​IMG]
    Maybe someone has a good pushing structure idea?
    I'm also thinking about letting this cylinder pushing against a loadcell, because i have any of them laying around. But they are only 50KG.
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    Last edited: Jan 13, 2015
  5. abs

    abs Active Member Gold Contributor

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    hello, iwas looking at your thread. I built also a diy hydraulic handbrake

    on ebay you can find for 50 us dollars the handbrake itself (structure ) without the hydraulic stuff (pipes, reservoir etc...) . just search hydraulic handbrake or Ebrake. regarding the sensor i also purchased it in ebay for about 40 dollars

    if you re interested i could give more details . I also used DSD tuto for the hardware.

    later on i used that knowledge to diy my cst pedals to turn the (load cell) foot brake into a hydraulic foot brake...
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  6. tombo

    tombo Active Member

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    Hello,
    thanks for your reply. I know you can buy it at ebay. But hre in Germany the parts arent that cheap. And since i work in a car garage and can get most parts for free, i will build it my self.
    The same is for the perssure Sensor. With postage and Taxes it's a lot more than 40 dollars here.
    Yesturday i recieved my pressure sensor and was able to find all the fittings i need. I just need 2 brake pipes and i can start testing. I'll post some pitures soon. Maybe you can show e a piture of yours?
  7. abs

    abs Active Member Gold Contributor

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    Hello Tombo,

    here is the pic of my hydraulic handbrake .

    an idea of improvement (but expensive) is to use a Measpec sensor (4 wire) and use DSD amplifier to amplify the signal.
    this wouls allow more control . I would have to dig that info somehwre in my stuff. I beleive nobody did it for hand brake . I was intending to do it on my foot pedal.
    here is the pic . for educational pupose i added a pic of my modded cst pedal (this uses the exact same principle but purchase a bracket , instructions were given to me also)

    IMG_0359.JPG IMG_0360.JPG
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  8. tombo

    tombo Active Member

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    Thanks for your pictures. The paddle thing looks very interesting.
    I've seen you have a pressure meter on your brakes.
    Did you measuered the pressure in the brakelines of the handbrake too? This would be very interesting for me.
    I see you also use the clutch slave cylinder. Would love to use it too but it's so expensive.
  9. abs

    abs Active Member Gold Contributor

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    Hello, there i a cheaper alternative to wilwoold cylinder in ebay or at summitracing . summitracing ship world wide. But i have to dig for the info.

    the meter i purchased it in ebay. could be a good add on to a rig to check pressure applied with a hand brake . I though that i should do it for the hand brake but i dont do that much rally . You have RBR (old game) and dirt (which i hate as it is arcady).
    i ll sent as much as info this WE
  10. tombo

    tombo Active Member

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    Hello,
    thanks for all your info. There is an alternative for cheaper slave cylinder in pulling type? I need the name, because i searched so much time for an alternative and didn't find any other pulling cylinder.
  11. abs

    abs Active Member Gold Contributor

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    Last edited: Feb 6, 2015
  12. tombo

    tombo Active Member

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    I taked a look at the cylinder you mentioned, but with shipping tax etc is much more cost than the whole handbrake will be :D
    so i decide to continue with my cheap pushing cylinder and will try it out.
    I did not made any process now, but charged up my flash for camera and wasable to take some pictures of the connectors and sensor. The connectors are with M10x1 to fit a normal brake line. So it will be very easy to combine the 2 cylinders.
    I get all the connectors at my local pneumatik shop for free.

    IMG_3514.jpg IMG_3516.jpg
  13. abs

    abs Active Member Gold Contributor

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    Looking forward to see how your project goes as one of my ideas is to do a diy hydraulic project with wilwood or (better) tilton pedals in the next few months. The less expensive the better
    Last edited: Feb 10, 2015
  14. Milton

    Milton Well-Known Member Gold Contributor

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    any updates on this project?
  15. pipis2015

    pipis2015 over-boost

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    its a fairly old thread but...

    @tombo
    1.2Mpa=170psi
    in case the press sensor you got is lower speced than the systems pressure you build.
    1)300psi-2Mpa
    http://www.ebay.com/itm/DC-5V-300-P...267612?hash=item3d0d5df99c:g:14YAAOSwX~dWhMQq

    2)500psi-3.5Mpa
    http://www.ebay.com/itm/Pressure-Se...538814?hash=item3aba3b1abe:g:Uo4AAOSwGotWhMQ1

    @abs
    whats your systems max capable pressure?
  16. abs

    abs Active Member Gold Contributor

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    hello ,
    with medium hard rubber /springs , i have a satisfactory realistic breaking at 400 psi

    you start to exert maybe too much pressure at 600 psi (seems unrealistic and not comfortable)
    (600 psi would be the max of my brake pedal without major flex on the modded cst)

    400 psi seems right and that what i use as maximum

    i used to use a sam sensor i switched to the measpec
    http://www.mouser.com/ProductDetail/TE-Connectivity/M3421-000006-01KPG/?qs=/ha2pyFadujnXsUEkkbp1RW4BUJe044g1PvJJbWAMm8=

    more expensive but give a slight but noticeable improvement of progressive response which i like. sam sensor is alo avery good mod/solution, dont get me wrong....
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  17. tombo

    tombo Active Member

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    Hello,
    yes the thread is very old, and i nearly give up with the Hydraulic handbrake, because of the connectors. They are hard to find and if i find some they are very high priced. I builded a loadcell handbrake now and it works very well for me.
  18. RacingMat

    RacingMat Well-Known Member Gold Contributor

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  19. eightbit

    eightbit Active Member Gold Contributor

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    Some very shmick looking handbrakes peeps! Keep us updated how you go.
  20. alberto_sv86_

    alberto_sv86_ New Member

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    Hi, where did you buy those elastomers?
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  21. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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