Master Brakes Assembly Instructions

Owned by Geoffrey Liu
Last updated: Jan 28, 2021
5 min read

https://docs.google.com/document/d/17mJquS8qxMZoYGSzsO0jx0aaeQfyn37hTHPAT_1yHV4/edit?usp=sharing

Assembly Instructions for the Main Brakes System (“Brakes_MasterLayout_Assembly_0000” in GrabCAD)

BOM

Number

Part Name

Quantity

Number

Part Name

Quantity

1

MSXIV-BRK001-Master Cylinder Plate

1

2

MSXIV-BRK002-Brake Pedal Face

1

3

MSXIV-BRK003-Brake Arm

1

4

MSXIV-BRK004-Pedal Mount Clevis

1

5

MSXIV-BRK005-Rod Coupler

1

6

MSXIV-BRK006-Brakes I Beam Mount

2

7

MSXIV-BRK007-Accel Pedal Mount

2

8

MSXIV-BRK008-Accel Pedal Mount Plate

1

9

MSXIV-BRK009-Brakes Mounting Top Plate

1

10

Master Cylinder

2

11

Accelerator Pedal Assembly

1

12

18-8 Stainless Steel Socket Head Screw M3 x 0.5 mm Thread, 22 mm Long

22

13

18-8 Stainless Steel Washer for M3 Screw Size, 3.2 mm ID, 7 mm OD

46

14

18-8 Stainless Steel Hex Nut M3 x 0.5 mm Thread

24

15

18-8 Stainless Steel Hex Drive Flat Head Screw M3 x 0.5 mm Thread, 12 mm Long

16

16

18-8 Stainless Steel Hex Drive Flat Head Screw M3 x 0.5 mm Thread, 14 mm Long

2

17

Female Threaded Hex Standoff 18-8 Stainless Steel, 6mm Hex, 12mm Long, M3 x 0.5mm Thread

4

18

Female Threaded Hex Standoff 18-8 Stainless Steel, 6mm Hex, 18mm Long, M3 x 0.5mm Thread

4

19

18-8 Stainless Steel Socket Head Screw M6 x 1 mm Thread, 30 mm Long

1

20

18-8 Stainless Steel Hex Head Screw M6 x 1 mm Thread, 40 mm Long, Partially Threaded

1

21

18-8 Stainless Steel Socket Head Screw M6 x 1 mm Thread, 40 mm Long

4

22

18-8 Stainless Steel Washer for M6 Screw Size, 6.4 mm ID, 12 mm OD

12

23

18-8 Stainless Steel Hex Nut M6 x 1 mm Thread

6

24

18-8 Stainless Steel Hex Head Screw M8 x 1.25 mm Thread, 45 mm Long, Partially Threaded

5

25

18-8 Stainless Steel Hex Head Screw M8 x 1.25 mm Thread, 30 mm Long

4

26

18-8 Stainless Steel Washer for M8 Screw Size, 8.4 mm ID, 16 mm OD

18

27

18-8 Stainless Steel Hex Nut M8 x 1.25 mm Thread

9

28

Corrosion-Resistant Ball Joint Rod End 5/16"-24 Internal Thread, Right Hand

2

29

18-8 Stainless Steel Threaded Rod 1/4"-28 Thread Size, 6" Long

1

30

18-8 Stainless Steel Washer for 1/4" Screw Size, 0.281" ID, 0.625" OD

2

31

18-8 Stainless Steel Hex Nut 1/4"-28 Thread Size, ASTM F594

2

32

5/16” J-sleeve Bearing

4

33

M8 J-sleeve Bearing

2

Instructions

  1. Join both Accelerator Pedal Mounts together using the 12mm long M3 flat head screws (#15) and the 12mm long M3 Standoffs (#17)

     

  2. Fasten the Accelerator Pedal Plate to the mounts using the 12mm M3 flat head screws (#15)

     

  3. Slide the Accelerator Pedal Mounts over the Accelerator Pedal Assembly, and fasten in place using the 30mm M6 bolt, washers, and nut (#19, #22, #23

     

     

  4. Join both Brakes I Beam Brackets together using the 12mm long M3 flat head screws (#15) and the 18mm long M3 Standoffs (#18)

     

  5. Attach the Master Cylinder Plate to the I Beam Brackets using the 22mm M3 socket head screws, washers, and nuts (#12, #13, #14)

     

  6. Thread on the 5/16” steel ball joint ends (#28) onto each Master Cylinder

     

  7. Fasten the Master Cylinders to the Master Cylinder Plate using the 30mm M8 bolts, washers, and nuts (#25, #26, #27)

     

  8. Align the Rod Coupler with the ball joint ends of the Master Cylinders and place the 5/16” bearings (#32) around both sides of the ball joints

     

  9. Insert the threaded rod (#29) through the ball joint ends and fasten in place on the Rod Coupler using the ¼” washers and nuts (#30, #31)

     

  10. Attach the I Beam Brackets and Accelerator Pedal Mounts to the Brakes Top Mounting Plate using the 22mm M3 socket head bolts, nuts, and washers (#12, #13, #14)

     

  11. Mount the Brakes Top Mounting Bracket to the chassis beams using the 45mm M8 bolts, nuts, and washers (#24, #26, #27)

    1. Note: Chassis tubes have slightly incorrect dimensions (off by < 1mm tube-lengthwise), need to make two mounting holes slots (holes closest to driver side, not front of car side)

       

       

  12. Locate the correct mounting location of the Pedal Mount Clevis on the front bulkhead (about 50mm from bottom face of chassis tubes) and fasten using 40mm M6 socket head screws, washers, and nuts (#21, #22, #23)

    1. Note: For mounting location on front bulkhead, consider drilling vertical slots instead of holes to ensure easy mounting adjustments

       

  13. Attach the Brake Pedal Face to the end of the Brake Arm using the 14mm M3 flat head screws, washers, and nuts (#16, #13, #14)

     

  14. Connect the Brake Arm to the Pedal Mount Clevis using the 45mm M8 bolt, washers, and nut (#24, #26, #27) through the pivot point

     

  15. Insert the M8 bushings (#33) into the Brake Arm’s slot and fasten it to the Rod Coupler using the 40mm M6 hex bolt, washers, and nut (#20, #22, #23)

    1. Easiest method would be to slide Rod Coupler out of the way to install bushings, then slide back and fasten

All done! Test Brake Arm movement and adjust pedal mount location if necessary