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Learning how to build Lotus Seven replicas...together!
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PostPosted: February 23, 2017, 7:56 am 
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Joined: March 19, 2011, 10:22 am
Posts: 826
Location: Holden, Alberta, Canada
Good day in the shop yesterday. Project - emergency brake assembly.
In order to build the emergency brake assembly I had to mock up the brakes. In order to do this I had to bolt the backing plates to the axle housing. In order to do this I had to pull the axles - I think you can see where I'm going with this, it takes a lot of pre work to get to the point of doing the job you want to do.
The OEM setup had the emergency brake cables entering the backing plates from the front, this was not acceptable on this application because of the trailing arms. So I swapped backing plates side to side, now the entry holes are on the rear of the plates.
Attachment:
File comment: Rear brake shoe mock up
IMG_1417.JPG
IMG_1417.JPG [ 126.38 KiB | Viewed 93 times ]


The OEM setup used a foot pedal, I choose a hand lever for this project simply to have more room in the DS foot well. I had to adapt the OEM cable for the hand lever by making up a threaded adjuster and swaging it on the cable. The hand lever cable I adapted is the longer cable in the pic.
Attachment:
File comment: Building new adjustable cable end
fullsizeoutput_344.jpeg
fullsizeoutput_344.jpeg [ 127.88 KiB | Viewed 93 times ]

Attachment:
File comment: Threaded adjuster rod swaged to cable
fullsizeoutput_342.jpeg
fullsizeoutput_342.jpeg [ 73.77 KiB | Viewed 93 times ]


Then it was just a matter of fabbing up a bunch of mounting br@cketz for the cables and locating them.
Attachment:
File comment: Cable entering rear of backing plate
IMG_1419.JPG
IMG_1419.JPG [ 122.81 KiB | Viewed 93 times ]

Attachment:
File comment: Cable housing br@cket
IMG_1420.JPG
IMG_1420.JPG [ 111.29 KiB | Viewed 93 times ]


I reworked the hand lever cable equalizer to accept the rear OEM cables.
Attachment:
File comment: Emerg brake cable equalizer assembly
IMG_1421.JPG
IMG_1421.JPG [ 120.68 KiB | Viewed 93 times ]


On this build I chose to use cable guides that go through the frame (they will be fully welded).
Attachment:
File comment: Emerg brake cable guides
IMG_1422.JPG
IMG_1422.JPG [ 121.31 KiB | Viewed 93 times ]


The following is just some pics of the installation from various views. I'll be securing the front cable to the side of the tunnel so that there will be no chance of it occupying the same space as the drive shaft.


Attachments:
File comment: Emerg brake lever mounted DS view
IMG_1423.JPG
IMG_1423.JPG [ 124.23 KiB | Viewed 93 times ]
File comment: Emerg brake lever mounted PS view
IMG_1426.JPG
IMG_1426.JPG [ 131.14 KiB | Viewed 93 times ]
File comment: Emerg brake lever and cable view from rear
IMG_1428.JPG
IMG_1428.JPG [ 128.15 KiB | Viewed 93 times ]
File comment: Emerg brake view PS
IMG_1429.JPG
IMG_1429.JPG [ 127.77 KiB | Viewed 93 times ]
File comment: Emerg brake view DS
IMG_1430.JPG
IMG_1430.JPG [ 133.25 KiB | Viewed 93 times ]

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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

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http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030
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PostPosted: February 23, 2017, 9:46 am 
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Joined: September 22, 2005, 8:12 am
Posts: 1266
Location: 4AGE in S.E. Michigan
Perry
The cable routing is very nice solution :cheers: Plus you locate the E-brake lever out of the way of your elbow :mrgreen: .
But I do not think you are playing fair! Maybe even cheating!!! You sure have a lot of space in that tunnel :lol:
Dave W


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PostPosted: February 23, 2017, 1:47 pm 
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Joined: May 27, 2006, 9:46 pm
Posts: 1521
Location: BC, Canada. eh?
Nice job! Isn't it amazing how details like these can take so much time? It's easy to get bogged down by some of this stuff. In retrospect, although it initially looked daunting, building the frame was the easy part!

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PostPosted: February 24, 2017, 12:21 pm 
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Joined: October 24, 2008, 2:13 pm
Posts: 2799
Location: Carlsbad, California, USA
That's a nice solution for the e-brake location, Perry.

Cheers,

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

Build Log: viewtopic.php?f=35&t=5886


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PostPosted: February 25, 2017, 12:07 am 
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Joined: October 6, 2009, 9:29 am
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Location: Tallahassee, FL (The Center of the Known Universe)
Nice work! Good placement of the e-brake lever. Perfect for those hand-brake turns... :twisted:

:cheers:
JDK

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Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
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