Brake Cable Mounting

Owned by Ahnaf Mamun
Last updated: Feb 22, 2024
4 min read

Here are some possible solutions for mounting the brake cable on the wheel side.

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Research

Info on our cable

Front Mounting Mechanism:

image-20240220-183717.png

  • An adjuster bracket is used to mount the wires before attaching them to the hand brake itself, something similar should be used on the other end to attach to the brake

 

The Back-End of Cable:

image-20240220-184145.png

  • Backing plate fittings along with nuts can be used in conjunction with a mount to fasten the cable

Examples of Brake Cable Mounting

  • Uses an angled mount to direct the brake cable to the connection point

  • Mount is very close to the connection point

  • Different types of connection points to what is used in our system

  • Mount is farther away from the connection point

  • Larger bend but the clevis is larger and secures the cable

Possible Solutions

All these designs are tentative and can be changed. Let me know of any feedback!

1. The Boomerang

Original Idea:

Model:

In assembly:

Notes (Pros and Cons):

  • Sheet metal thickness and hole size for brake cable are arbitrary for now

  • Hole locations may be an issue (too close to the edge)

  • The brake cable connection is low and close to the connection point

  • Odd shape, could be water jetted

2. Round-House

Model:

In assembly:

Notes (Pros and Cons):

  • Sheet metal thickness and hole size for brake cable are arbitrary for now

  • The distance between where the cable needs to be connected and where the mount is located could be too large

  • The hole for the brake cable in the mount could be too high causing a large bend for the brake cable to reach the parking brake

    • Maybe alter the design to follow the geometry of the original idea more closely

3. Take the L

Model:

In assembly:

Notes (Pros and Cons):

  • Sheet metal thickness and hole size for brake cable are arbitrary for now

  • The brake cable connection is low and close to the connection point

  • Only fastened with one bolt, could make it weaker

  • Uses less material

4. L-Bracket (Concept)

This is a more conceptual design that would use an off-the-shelf product to route the cable.

Example of bracket that could be used:

Update + Possible Issues:

Interference:

After a discussion with Matthew to save on material costs the thickness of the piece should be 3/8in (to fit on stock metal). However, this causes issues mainly with interference, as seen in the model below the “boomerang” has interference between itself and the parking brake caliper and a slight interference with the angled brake.

Possible Solutions:

  • Interference is very small, could possibly take off material from parking brake mount.

  • Thinner metal for mounting plate, not sure what sheet metal we have in house, I can check if we have some scrap that could fit this piece (it can fit in a 107mmx68mm square)

Conclusion:

  • Altered the design of the boomerang making it skinnier where it interference with the angled caliper mount (around the top-most hole)

  • Instead of using aluminum for this part, we will most likely use steel because we have thinner stock material so no interference between the brake cable mount and parking brake mount

  • FEA will be done on this rendition of the part to see how much force it can take

Bolt Size:

This issue pertains to whether there is enough clearance for a bolt to fit as the brake caliper and mounting plate are close together.

Here are some screenshots that use different high & low-profile bolts and nuts: