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  1. DerekSpeare

    DSD Hydraulic Handbrake DIY Project

    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): Pull cylinder (42USD): Wilwood 260-1333 pull cylinder: Sam Sensor (36 USD) - 1000psi only Controller (40USD) Master cylinder reservoir (50USD) Tilton Remote Reservoir #260-11098 (20USD) 7/16-20 to AN4 fitting: (5USD) Brake Lines: (30USD) Fragola T-fitting: (10USD) Bushing: (9USD) 3/8-24 INV to -3AN Fitting (2pcs - 9USD) 90 elbow Fragola Performance Systems Couplers 496303: Other Needs: Brake Fluid - Dot 4 Teflon Tape 3-Pin Female Arduino Connector 3/8" washers wrenches and other hand tools Soldering iron