Rear hydraulic brake system hookup [HELP]

[Nodroz]

Hello,

I included a picture of a similar brake system of what I have. I mounted my caliper already, but now I have to hook up the master cilinder to the brake pedal. However, I am out of ideas how to do this. Can somebody help me inventing a system to control the master cilinder using my brake pedal? (Just an ordinary pedal)

Also, does this master cilinder have to be vertical mounted? Would it give problems if I mount this horizontal? The only problem I could figure out is that you can't fill the cilinder without dissambly...

So, does anybody have any good ideas for me how to hook this up?

PS. The hydraulic brake line is too short to reach the front of the gokart. The master cilinder will be located somewhere in the middle of the gokart.

Please help,
Alex

 

[OzFab]

It should be fine horizontal (well, I hope so anyway, that's how I'm mounting mine)

You're going to need either a rod or a cable to go from the pedal to the master; a clutch cable from the same bike can be used.

Depending on which way you mount it (rod facing forward or back) depends on how you mount your pivot bar. Oh, did I mention, you'll need a piece of flat bar, a bolt & a nyloc nut to act as a pivot to attach the cable or rod to the master.

Basically, the cable end attaches to one end of the flat bar. If the master rod faces forward you want the pivot bolt between the cable & master rod. If the master rod faces back, you want the pivot on the end & the master rod in the middle.

I hope that makes sense... if not. let me know & I'll draw a diagram

 

[Doc Sprocket]

Gimme a bit of time- I just finished mocking up the brakes on the Weed Warrior- I'll put up a pic.

 

[Nodroz]

It should be fine horizontal (well, I hope so anyway, that's how I'm mounting mine)

You're going to need either a rod or a cable to go from the pedal to the master; a clutch cable from the same bike can be used.

Depending on which way you mount it (rod facing forward or back) depends on how you mount your pivot bar. Oh, did I mention, you'll need a piece of flat bar, a bolt & a nyloc nut to act as a pivot to attach the cable or rod to the master.

Basically, the cable end attaches to one end of the flat bar. If the master rod faces forward you want the pivot bolt between the cable & master rod. If the master rod faces back, you want the pivot on the end & the master rod in the middle.

I hope that makes sense... if not. let me know & I'll draw a diagram

That makes sense. Thank you.

Would I be fine to just weld on a bolt upside down (flat top onto the frame). Then drill a hole in the middle of a 8cm long piece of flat metal. Put a washer on, and then a nylon nut. I'll be sure not to tighten it too hard, the metal bar still needs to be able to pivot.
Attach the brake cable, coming from the pedal to one side of the bar. Then attach the other side of the metal bar to the cilinder.

Just wanted to make sure I understood it correctly.

Gimme a bit of time- I just finished mocking up the brakes on the Weed Warrior- I'll put up a pic.

Thanks, don't forget!

 

[OzFab]

You understand perfectly

That bolt idea will be fine.

Here's a pic:

 

[Doc Sprocket]

Yup- That's about it. Here is essentially the same thing on my tractor. Note that it's still in mockup, so it hasn't been cleaned up or tweaked yet. M/C is from a 1983 Honda Interceptor 750. First pic shows the pedal and actuating rod- in this case, the rod pulls. Second pic shows the bellcrank and master cylinder. The bellcrank changes the pull into a push, depressing the plunger in the M/C.

 

[Nodroz]

Thanks for the pictures. I will try out tomorrow.

 

[mr.matt]

Here is a different way, I reversed the way the master sits so rather than pushing with the rod, it pulls.

 

[Nodroz]

Still wondering if it's good to mound mine horizontal? The filler cap is at the top when you mount it vertical. When I mount horizontal, I'll never be able to fill it without dissambly...

Are you sure it would work horizontal aswell? There might be issues with air?

Thanks mat for the pictures btw!

 

[Doc Sprocket]

It should be okay, but it's not a chance I would take. Instead, mount it vertically. Now- you saw my bellcrank, and Fab's too. They are 180* bellcranks, as they change the direction of travel by 180*. YOU would instead make a 90* bellcrank- basically shaped like an "L". The pivot is in the middle where the two arms come together. The input and outputs would be on the end of each leg. If this L was your bellcrank, you would run a rod from the upright (|) horizontally to the pedal, and a rod from the lateral piece (_) vertically to the master cylinder. Clear as mud, right?

 

[OzFab]

A bit like this, only vertical?

 

[spyder1968]

vertical wouldn't matter if you have a small remote reservoir

 

[Nodroz]

Thanks for the answers. I got it mounted vertical. Wasn't that hard after following Fabroman's and everybody else their advice! Thank you.

Pictures can be seen in my dirt Devil build thread: http://www.diygokarts.com/vb/showthread.php?t=18590