DSD Hydraulic Handbrake DIY Project
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126 posts in this topic

Guys, it took me a long time, but I finally got a handbrake up and running. Having never dealt with hydraulics before, I was having leaks all over, despite PTFE tape. It was torture, but in the end, it was totally worth it.

Now, a whole new skill to learn. In Dirt Rally, I much preferred the RWD cars, because I couldn't make tight turns in others. Now with the handbrake, that skill is coming together, and so many more cars are fun to drive now.

One issue. I went with a low priced universal handbrake I found online. I regret it. It's a cheap knockoff for sure. Firstly, it has tons of slop. I have a motion platform (D-box), so parts with slop rattle around a lot. I'd like to minimize that if possible. (BTW, Dirt Rally is the best supported motion game I have ever played. It is AWESOME.)

More importantly however, the actuator sticks like crazy, despite lubrication with lithium grease, (which helps a lot, but doesn't solve the problem). This compromises consistency.

Can someone link me a universal handbrake they can vouch for? I prefer one like Derek's Handbrake V2 and Inky's build, as it will be a 1:1 replacement for what I've already pieced together.

Thanks guys.

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5 hours ago, esteady1 said:

One issue. I went with a low priced universal handbrake I found online. I regret it. It's a cheap knockoff for sure. Firstly, it has tons of slop. I have a motion platform (D-box), so parts with slop rattle around a lot. I'd like to minimize that if possible. (BTW, Dirt Rally is the best supported motion game I have ever played. It is AWESOME.)

 

I had similar issue, and to fix that I used cold water tap washer on axle. Now nothing rattles.

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On 07/05/2016 at 0:05 PM, Tofi said:

I used arduino leonardo and MMjoy2. It was working perfectly. Was because had some leaks and now handbrake covers with dust on shelf because of insufficient time for second try. This time i had bought ticker teflon tape. Can anyone tell how to perfectly build the hoses without leaks? On youtube are tutorials only for some thick hoses and fittings for AN3 are slightly different from them. should I put some ptfe tape? in which places?

Can you get the MMjoy2 working with Dirt Rally? I have an Issue where I can assign the key in Dirt Rally, and it works doing a stage. But it will not work in the start of a stage, it just keeps asking me to hold the handbrake. But it works fine in any other game, and in any other situation than the start of a normal rally stage in Dirt Rally.

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3 minutes ago, AgapeN said:

Can you get the MMjoy2 working with Dirt Rally? I have an Issue where I can assign the key in Dirt Rally, and it works doing a stage. But it will not work in the start of a stage, it just keeps asking me to hold the handbrake. But it works fine in any other game, and in any other situation than the start of a normal rally stage in Dirt Rally.

You do need to pull 100% on the handbrake axis at the start of the stage so maybe you are not getting full 100%

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I have tried that, it tells me that is a 100% in windows, when pulling with that force. and that is why I'm asking. but will try recalibrating it again and see if that makes a difference

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hey guys!

so ive got this controller:

http://www.ebay.de/itm/Zero-Delay-Arcade-USB-Encoder-PC-to-Joystick-MAME-5Pin-Sanwa-Push-Button-AC425-/222184570802?hash=item33bb3b7fb2:g:AQIAAOSwAPlXh3Id

 

can i somehow connect this pressure sensor:

http://www.ebay.de/itm/1000psi-Drucksensoren-Druck-Sensor-fur-Brennstoffe-Ol-Kraftstoff-Diesel-Gas-Luft-/401136248108?hash=item5d6595652c:g:DvUAAOSwtJZXXo4t

to it and get a analog signal?
 

please give me a tutorial:)

 

and can i just screw the pressure sensor into the handbrakes master cylinder and get the analog signal by air pressure?

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3 hours ago, HowtoDrift said:

hey guys!

so ive got this controller:

http://www.ebay.de/itm/Zero-Delay-Arcade-USB-Encoder-PC-to-Joystick-MAME-5Pin-Sanwa-Push-Button-AC425-/222184570802?hash=item33bb3b7fb2:g:AQIAAOSwAPlXh3Id

 

can i somehow connect this pressure sensor:

http://www.ebay.de/itm/1000psi-Drucksensoren-Druck-Sensor-fur-Brennstoffe-Ol-Kraftstoff-Diesel-Gas-Luft-/401136248108?hash=item5d6595652c:g:DvUAAOSwtJZXXo4t

to it and get a analog signal?
 

please give me a tutorial:)

 

and can i just screw the pressure sensor into the handbrakes master cylinder and get the analog signal by air pressure?

That controller won't work as it doesn't have an analogue input and no you can't use that pressure sensor with air alone as you will never get the required pressure for it to register. That is a 1000psi pressure sensor after all.

Edited by inky99

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9 minutes ago, HowtoDrift said:

Ok which Board do you recommend?

It shouldnt be too expensive like 40 or 50€...

 

So how much psi do i need if i want to do it with air?

I used the leobodnar board.

http://www.leobodnar.com/shop/index.php?main_page=product_info&cPath=94&products_id=204&zenid=6dc45596f4978698f0f01abd3de92e34

It's only £25.

As far as the pressure sensor I am not sure what will work with air as I haven't tried it. For the price of a small slave cylinder it's worth doing it properly. If you look back through my posts you will find a parts list that I posted which includes prices and where purchased. Give it a look.

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Look back through this thread and all the info you need is there. You will need a reservoir and a slave cylinder. The sensor just connects to one of the analogue channels on the leobodnar board with 3 wires.

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4 hours ago, inky99 said:

Look back through this thread and all the info you need is there. You will need a reservoir and a slave cylinder. The sensor just connects to one of the analogue channels on the leobodnar board with 3 wires.

Does it work like this?

 

Edited by HowtoDrift

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6 hours ago, HowtoDrift said:

Ok which Board do you recommend?

It shouldnt be too expensive like 40 or 50€...

 

So how much psi do i need if i want to do it with air?

You can't use air because it is compressible, you wouldn't get much of a pressure reading until the master cylinder fully bottoms out, if the design of the master cylinder allows this at all, You need to use brake fluid

 

4 hours ago, HowtoDrift said:

For what do i need the Slave Zylinder?

Ive got a pressure spring so it feels better when i pull on the handbrake lever

.The slave cylinder is used to compress the rubber bumpers to give you the resistance you would feel in a real car, there are other ways you can do this like with the brake calipers that others have used in this thread.

 

1 hour ago, HowtoDrift said:

Does it work like this?

 

Basically, you just need to connect the +5V, GND and Analog up to the Leo bodnar board and it will work. 

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18 hours ago, Avenga76 said:

You can't use air because it is compressible, you wouldn't get much of a pressure reading until the master cylinder fully bottoms out, if the design of the master cylinder allows this at all, You need to use brake fluid

 

.The slave cylinder is used to compress the rubber bumpers to give you the resistance you would feel in a real car, there are other ways you can do this like with the brake calipers that others have used in this thread.

 

Basically, you just need to connect the +5V, GND and Analog up to the Leo bodnar board and it will work. 

thank you so much:D

but i still have a question.

 

1.If i use a reservoir and put brake fluid in it can i just screw the pressure sensor into the master zylinder via a adapter (already found on on the internet that should work)?

 

 

2.How much psi do i need if i want to do it with brake fluid?

 

3.if i use this arduino board https://www.amazon.de/Elegoo-R3 ATmega328P-ATmega16U2 Board-Compatible-ARDUINO/dp/B01EWOE0UU/ref=sr_1_1?ie=UTF8&qid=1472839163&sr=8-1-spons&keywords=arduino+board&psc=1

can i just go ingame and the analog signal will work or do i need to do any coding or something?

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1.If i use a reservoir and put brake fluid in it can i just screw the pressure sensor into the master zylinder via a adapter (already found on on the internet that should work)?

You can but you won't have that squishy feeling that you get with a normal handbrake as it squeezes the brake caliper. Because brake fluid is non compressible it will just build up pressure straight away and be really stiff.

 

2.How much psi do i need if i want to do it with brake fluid?

1000PSI

3.if i use this arduino board https://www.amazon.de/Elegoo-R3 ATmega328P-ATmega16U2 Board-Compatible-ARDUINO/dp/B01EWOE0UU/ref=sr_1_1?ie=UTF8&qid=1472839163&sr=8-1-spons&keywords=arduino+board&psc=1 can i just go ingame and the analog signal will work or do i need to do any coding or something?

You will need to do coding. You could use an Arduino but you would have to use some joystick emulation code on the Arduino.

The problem with the Arduino is that it talks to the PC via serial so it doesn't show up as a normal game controller, you need to do something like this to make it work http://www.instructables.com/id/Using-an-Arduino-Uno-R3-as-a-Game-Controller/

Even that is sub-optimal because their code adds a 100ms delay between reads and you need to have java convert the serial in to something usable and then they run another program to get the game to detect it. There are other ways but they are all a bit clunky and they won't be as fast or as good as a proper game controller 

It is much easier and better to by a proper game controller like the bodnar board http://www.leobodnar.com/shop/index.php?main_page=product_info&cPath=94&products_id=204&zenid=6dc45596f4978698f0f01abd3de92e34

or the DSD 12bit without loadcell amp http://www.derekspearedesigns.com/12-bit-controllers.html

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7 hours ago, Avenga76 said:

1.If i use a reservoir and put brake fluid in it can i just screw the pressure sensor into the master zylinder via a adapter (already found on on the internet that should work)?

You can but you won't have that squishy feeling that you get with a normal handbrake as it squeezes the brake caliper. Because brake fluid is non compressible it will just build up pressure straight away and be really stiff.

 

2.How much psi do i need if i want to do it with brake fluid?

1000PSI

3.if i use this arduino board https://www.amazon.de/Elegoo-R3 ATmega328P-ATmega16U2 Board-Compatible-ARDUINO/dp/B01EWOE0UU/ref=sr_1_1?ie=UTF8&qid=1472839163&sr=8-1-spons&keywords=arduino+board&psc=1 can i just go ingame and the analog signal will work or do i need to do any coding or something?

You will need to do coding. You could use an Arduino but you would have to use some joystick emulation code on the Arduino.

The problem with the Arduino is that it talks to the PC via serial so it doesn't show up as a normal game controller, you need to do something like this to make it work http://www.instructables.com/id/Using-an-Arduino-Uno-R3-as-a-Game-Controller/

Even that is sub-optimal because their code adds a 100ms delay between reads and you need to have java convert the serial in to something usable and then they run another program to get the game to detect it. There are other ways but they are all a bit clunky and they won't be as fast or as good as a proper game controller 

It is much easier and better to by a proper game controller like the bodnar board http://www.leobodnar.com/shop/index.php?main_page=product_info&cPath=94&products_id=204&zenid=6dc45596f4978698f0f01abd3de92e34

or the DSD 12bit without loadcell amp http://www.derekspearedesigns.com/12-bit-controllers.html

Ok thanks for the fast answer

Is there any cheaper Alternative then the leobodnar and the dsd Controller?

I've got a spring so it feels a Bit betterb when i pull on the handbrake and i havent got enough Money for the Slave cylinder...

 

Can you please explain to me why i need a 1000 psi pressure Sensor?

just  curious:D

 

 

Edited by HowtoDrift

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Is there any cheaper Alternative then the leobodnar and the dsd Controller?

 

Not that I am aware of, those are about the cheapest I can find.

 

Can you please explain to me why i need a 1000 psi pressure Sensor?

 

Because the handbrake can pull over 500 PSI. I have mine calibrated at around 450 PSI but if I pull on it really have I can get it up to around the 600-700 PSI range. If you went for a 500 PSI then you could max out the sensor if you pull the handbrake too hard, the 1000 PSI is the perfect size.

Because of the mechanical advantage of the handbrake lever and the non-compressablity of the brake fluid you are able to produce some really high pressures, this is why you see brake lines that are rated for 3,000 PSI. If you were to slam on your foot brake in a road car you could be pulling around 1,200 to 1,500 PSI. race cars are even higher.

It takes a lot of force to stop a car so there is a ton of pressure in that brake system.

 

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2 minutes ago, Avenga76 said:

Is there any cheaper Alternative then the leobodnar and the dsd Controller?

 

Not that I am aware of, those are about the cheapest I can find.

 

Can you please explain to me why i need a 1000 psi pressure Sensor?

 

Because the handbrake can pull over 500 PSI. I have mine calibrated at around 450 PSI but if I pull on it really have I can get it up to around the 600-700 PSI range. If you went for a 500 PSI then you could max out the sensor if you pull the handbrake too hard, the 1000 PSI is the perfect size.

Because of the mechanical advantage of the handbrake lever and the non-compressablity of the brake fluid you are able to produce some really high pressures, this is why you see brake lines that are rated for 3,000 PSI. If you were to slam on your foot brake in a road car you could be pulling around 1,200 to 1,500 PSI. race cars are even higher.

It takes a lot of force to stop a car so there is a ton of pressure in that brake system.

 

ok thanks so much:D

will it make a big diffrence if i use the arduino?

i mean its only 100 ms slower right?

im gonna use it for drifting mostly

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If you are happy with mucking around with the code on the Arduino then it might be okay.

It might be worth having a hunt around to see if you can find any other cheaper USB game controllers that will work natively so you don't have to mess around with code

 

 

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23 minutes ago, Avenga76 said:

If you are happy with mucking around with the code on the Arduino then it might be okay.

It might be worth having a hunt around to see if you can find any other cheaper USB game controllers that will work natively so you don't have to mess around with code

 

 

ok thanks:D

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Hi!

I believe, the arduino Leonardo is a good alternative. You can get the micro version for around 8€!  (note: the arduino board must have this chip  ATmega32u4 to be able to work as a USB controller)

My doubts, since i don't understand well about programing and electronic, is the resolution from the arduino... But if you are doing a handbrake on the cheap and the handbrake don't need that much resolution, the Arduino is a good option.

http://www.instructables.com/id/Arduino-LeonardoMicro-as-Game-ControllerJoystick/?ALLSTEPS

http://www.goblogpdx.com/blog/arduino-to-usb/

 

PS: I have in the racedepartment forum a Low cost slave cylinder alternative check it out if it is useful:

http://www.racedepartment.com/threads/diy-low-cost-slave-cylinder-for-hydraulic-brake-handbrake.124929/

 

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2 hours ago, Avenga76 said:

If you are happy with mucking around with the code on the Arduino then it might be okay.

It might be worth having a hunt around to see if you can find any other cheaper USB game controllers that will work natively so you don't have to mess around with code

 

 

would this work?

https://www.amazon.de/ATmega328P-Mikrocontroller-USB-Controller-Arduino-kompatibel/dp/B01H6YXBRG/ref=sr_1_3?ie=UTF8&qid=1472918120&sr=8-3&keywords=arduino+controller

since it says that its a usb controller?

will it be recognized as a controller on the pc then?

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