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DSD Hydraulic Handbrake DIY Project
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126 posts in this topic

Hi folks,

I'm asked frequently if I'll offer a handbrake, and so far, that's been a component I've considered but never had time to develop.  I've been thinking in the past so many months that a DIY handbrake project would be a good place to start my initial evaluation of the feasibility of adding such a component to my line of sim racing components.  

The scope of this DIY Hydraulic Project is one where anyone who wants such a component can build one with simply off the shelf components.  My initial goal was to add the constraint of making it a "Zero Fab" effort, and other than drilling a couple of holes, I've accomplished that as well.

The Hydraulic Handbrake uses the methods developed by Emery Emond.  His method involves using a brake master cylinder connected to a pull cylinder fitted with urethane bushings - ALL Hydraulic systems adapted for sim racing use employ his method.  The system pressure is measured directly with a pressure transducer.  This is an ingenuous method, and one he uses on all of his Tilton Pedal systems (found in professional racing sim rigs and other high end sim racing systems).  Without Emery's method, this handbrake project would not be hydraulic and would be much harder to accomplish like I'd like and how many would expect.  

The DIY Project has photos showing the system along with a detailed parts list which you can use to simply purchase your parts and assemble them into a fully functional, stand alone USB handbrake.  It's easier than you'd think, and it's a pretty cool component.  

The scope of the project is not to provide hands on instruction on how to put it together - I'll expect thos who want to build their own to muster the "DIY Spirit" and DO IT Yourself.  Also, the scope of the project is not to elicit feedback for alternate ideas, methods or solutions.  What I am providing here is what I believe a reasonable sim racer would think is properly planned and excuted.  Some may have other ways, and to them, I encourage them to make their own way for their own project.

 

Parts List:

 

Handbrake lever and assembly (60 USD):

http://www.ebay.com/itm/HYDRAULIC-DRIFTING-RACING-RALLY-HAND-E-BRAKE-HANDBRAKE-VERTICAL-HORIZONTAL-SILVE-/350747599694?pt=Motors_Car_Truck_Parts_Accessories&hash=item51aa2fa34e&vxp=mtr

Pull cylinder (42USD):

http://www.ebay.com/itm/Pull-Type-Wilwood-Style-Slave-Cylinder-IMCA-/360761639472?pt=Race_Car_Parts&hash=item53ff11c230&vxp=mtr

Wilwood 260-1333 pull cylinder:

http://wilwood.com/MasterCylinders/MasterCylinderProd.aspx?itemno=260-1333

Sam Sensor (36 USD) - 1000psi only

http://www.ebay.com/itm/Pressure-transducer-sender-1000-psi-for-oil-fuel-air-/250957430320?pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr&hash=item3a6e3a7e30

Controller (40USD)

http://www.derekspearedesigns.com/circuits

Master cylinder reservoir (50USD)

https://www.pegasusautoracing.com/productdetails.asp?RecID=1123

Tilton Remote Reservoir #260-11098 (20USD)

http://www.summitracing.com/parts/wil-260-11098

7/16-20 to AN4 fitting: (5USD)

http://www.summitracing.com/parts/aaf-all50032

Brake Lines: (30USD)

http://www.summitracing.com/parts/ear-63010111erl

Fragola T-fitting: (10USD)

http://www.summitracing.com/parts/fra-599903

Bushing: (9USD)

http://www.summitracing.com/parts/ens-9-8105r

3/8-24 INV to -3AN Fitting (2pcs - 9USD)

http://www.summitracing.com/parts/ear-581531erl

90 elbow Fragola Performance Systems Couplers 496303:

http://www.summitracing.com/parts/fra-496303

Other Needs:

Brake Fluid - Dot 4

Teflon Tape

3-Pin Female Arduino Connector

3/8" washers

wrenches and other hand tools
Soldering iron

 

dsdhydhb.png

 

HPIM1708.jpg

 

HPIM1707.jpg

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The frex uses the same brake mechanism, commonly found from HK and China.  Their device is a load cell action.  What I've posted here is a full and complete DIY list so anyone can make their own hydraulic hand brake, and other than the mechanism being the same, this is nothing like the Fres.

 

Of course, we sell a finished one, but the DIY guide was posted in the spirit of building community value.  Have fun with your project. 

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Anything that looks like the Frex is good

 

Mate, you're right. Haven't noticed that before, main part of the base, lever and connection is identical.

It's a bit weird, because Frex is saying on their website it's hydraulic. A mate of mine got it and I should actually know because I've tried it - shame on me;-)

It looks pretty flash. The downside of this base-lever unit is that there's just too much play in it imo. The lever feels just too wobbly or loose for my taste. I actually thought that's where the DSD one has an advantage.

My recommendation would be: try it out and see for yourself if that's an issue.

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Mmmh i looking around about a good handbrake and ask in my thread  but nobody can give me a good information 

 

The arc modell what i used/tested at first was not my favorite for action because of the to slow responding

 

The problem is you become nowhere information or feedback about this parts :???::

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Hi Derek, 


First off, thanks for the amazing products and information you've provided the sim racing community, truly amazing stuff. I've been tempted to build something like what you've shown above, but using old car parts to keep it on the cheap. I just had one question that I can't seem to find an answer for in your post. The bracket you've used to hold the slave cylinder to the master cylinder, was that something you had to fabricate ? I think I'll go with a simple solution, but if it's something off the shelf, then I'm all ears. Thank again !

 

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Thanks a ton for posting this Derek. I just put together my own e-brake and plugged it right into my CSR Elite pedals and everything is working fantastically. Thanks for putting this info. out here for everyone to see, myself and I'm sure a lot of others really appreciate it. 

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Thanks a ton for posting this Derek. I just put together my own e-brake and plugged it right into my CSR Elite pedals and everything is working fantastically. Thanks for putting this info. out here for everyone to see, myself and I'm sure a lot of others really appreciate it.

 

How did you get it so you could plug the handbrake into the pedals?

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I could see your fingers getting caught up in that CNC handbrake pretty easily. I would prefer a solid handle.

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Derek/Steve does any USB controller work with this or is there a specific one that is needed?

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Any USB controller with Axis will work. So something like the DSD Micro32 button controller wouldn't work, but the DSD 12 bit controller would work fine.

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Cheers Avenga, glad I asked I was going to tear out a board from one of my wheels

Thanks

 

BTW Avenga, have you ever seen something similar for a sequential shifter? I love the floor mounted Manu factory sequential shifter but less so the price.  Have you seen anything similar that could be modded DIY for less than the cost of the Manu shifter?

Edited by UNKLE

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Great take on Derek's design Steve, really liking this!

I've had a simpler, slave-less version of a handbrake for a few years and now feel I must add a slave cylinder, so going to ask if you would be kind enough to give links, if you have them of course, for the brake pipes and any connectors/adapters, if any used and what the are, exactly. I assume any type of clutch  slave cylinder will do, with a standard  3/8-24 inlet

All these 3/8-24 and other UNF and NPT standards and terms are a little alien to me, so I wanna forage eBay for these parts

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Great take on Derek's design Steve, really liking this!

I've had a simpler, slave-less version of a handbrake for a few years and now feel I must add a slave cylinder, so going to ask if you would be kind enough to give links, if you have them of course, for the brake pipes and any connectors/adapters, if any used and what the are, exactly. I assume any type of clutch  slave cylinder will do, with a standard  3/8-24 inlet

All these 3/8-24 and other UNF and NPT standards and terms are a little alien to me, so I wanna forage eBay for these parts

doh, as it happens, I seem to be learning fast, hehe. EBay basket nearly complete, Ithink iI might be all set actually

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doh, as it happens, I seem to be learning fast, hehe. EBay basket nearly complete, Ithink iI might be all set actually

can you post your links to those items as I am in the same position as you, cheers

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Sure. I'm UK based, so I picked cheapest available locally

Bushings

http://www.ebay.co.uk/itm/281055830530

slave clutch cylinder

http://www.ebay.co.uk/itm/331321436093

Brake lines

http://www.ebay.co.uk/itm/191680364573

Tee joint

http://www.ebay.co.uk/itm/360570123470

my transducer:

http://www.ebay.co.uk/itm/181138035088

 

And you'd need an adapter for its connection to the tee. I used these long time ago, it's us based. You may want to find a tee with 1/8 option instead, I just went with 3 way 3/8 unf because I already have this adapter for it to be used for the transducer

http://www.ebay.co.uk/itm/391228147281

Please note - this is what I came up with and ordered at 5am, so I may well finding something to be wrong or missing, but I'm hopeful :)

Edited by frapster

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@steveS

if you like the handbrake so much you can order the handbrake direct from china over the shop aliexpress.com... its much cheaper then from ebay!!
in allow:
http://de.aliexpress.com/item/EPMAN-Universal-Jdm-Hydraulic-Horizontal-Rally-Drifting-E-brake-Lever-HandBrake-Sliver-EP-B88008SL/32413385886.html?ws_ab_test=searchweb201556_2_79_78_77_91_80,searchweb201644_5,searchweb201560_9
in black:

http://de.aliexpress.com/item/EPMAN-Black-Adjustable-Aluminum-Vertical-Hydraulic-Drifting-Hand-Brake-With-Special-Master-Cylinder-S14-S13-EP/32432989014.html?ws_ab_test=searchweb201556_2_79_78_77_91_80,searchweb201644_5,searchweb201560_9

will build a e brake with this in the next month^^

edit:
the link work not again!!! i F***ing hate the new forum!!! copy the links to your browser or just search in aliexpress.com for epman hydraulic handbrake or just hydraulic handbrake.... it gives huge price diferences!!!

 

Edited by BattleGear

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Very nice Steve! sorry to keep repeating myself :)

While the original discussion at Gtplanet a few years ago in a similar thread with Derek inspired me back then (thanks again for all the advice Derek!) to make a simplified slave-less version of it with just the transduxer sitting on the master cylinder, your cheaper/fewer components version has now inspired me to add a slave cylinder and the rest. Thanks for that, as per above few posts it was easier for me to make my own plan and list of components.

i'm rather happy with the result and how quickly i managed to do planning, sourcing and putting it together

Edit: darn, quoted tthe wrong post (the suffering one is subjected to composing posts on a phone), meant the last post of Steve here

 

20151106_205156_resized.jpg

Edited by frapster

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@ BattleGear, wow what a price difference, thank you that's very tempting!

 

Frapster the handbrake looks great, very creative & solid setup. Very sorry for not replying, I have been a bit poorly lately...

Nice to see so many people doing this project given the new popularity of Rally...

Edited by SteveS

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On 15/07/2015, 00:32:43, SteveS said:

MrBasher documented the connection on the clubsport circuit.

https://www.gtplanet.net/forum/threads/clubsport-and-csr-elite-pedals-handbrake-diy-info.280445/

I wonder if anyone here has the wiring diagram for Clubsport Handbrake, I'm interested in plugging my hydro HB into my V3 pedals instead of current attachment to my button box with Bodnar board. I do mean the wiring for RJ12 6-pin connector it uses.

Would appreciate if anyone had tried adapting an axis driven handbrake to those pedals port and knows where the +, the signal and the GND wires go on the 6 pin connector and don't mind sharing

Edited by frapster

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