The handbrake lever upgrade "plus"

deQuincey

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The misalignment of the handbrake lever is a common issue in the e3 and e9, when handbrake is at rest you know you can move the lever horizontally up to 2cm in each direction (right and left)

After thinking and rethinking about the "paul cain" handbrake upgrade, very wise solution, I have come to a more elaborated, but still simple "upgrade +" solution

you will be the judge



I have just installed and it works great !!!

explanations and pictures to follow...
 

deQuincey

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this is the starting point, the original mechanism:



a schematic drawing of this mechanism:



and the new system installed:
 

deQuincey

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the well known actual upgrade uses a M14 bolt to substitute the original diam. 14mm axis, and here comes part of the problem, it is not really good to pivot metallic parts against a bolt thread, it is better to plan a flat contact surface, so my redesign includes an M12bolt together with bushings:

this is the procedure:

I start with a half threaded stainless steel bolt M12x100, (yes it is a long bolt, but I need a large unbolted area to work in)



I do a extended thread until having only the required flat area for the bushings







when the flat area is enough (0,5mm less than the required lenght ), then cut the total lenght as short as the nut requires



standard bushings int. diam. = 12, ext. diam. =14 (available at industrial hardware stores)




.


I saw the bolt head to reduce the lateral interference with the handbrake cover



selfblocking nut



include the needle roller bearings and washers and use a dab of good LM grease:

 

deQuincey

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assembly tips

this is not an immediate straighforward assembly but with a few tips, it is perfectly doable.

this must be the first step:

first tip, use duct tape to fix the button in the "pressed" position, this releases the lever: (do not place it in vertical position as is pictured, it will be much more difficult to go back to its place (this is what I learned, my mistake))





try to avoid the rachet to fall into the hole, you can pick it again but it will cause some inconvenience




remove the actual axis:



use the new bolt to help you:




remove the handbrake light switch: (take the advantage and clean it)



remove the cables, you will need this to move the lever back and forth in order to install the bearings

before removal paint the position to repeat it:






then move the lever a bit backwards as needed to introduce the bearings





then hold the rachet from behind with a screwdriver and start introducing the bolt:



place the nut and tighten gently, but not too much (from time to time check the lever free play)



introduce the cables and tighthen the nuts, and thats all !

now enjoy the new super-smooth and precise movement of your new upgraded handbrake lever !!

enjoy
 
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Nicad

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Well documented mod post as usual. Where did you source that Needle bearing? Is there a part number on it? I hope to dig this thread up in about year 5 of my Coupe ownership. It won't be complete till this is done.
 

deQuincey

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Well documented mod post as usual. Where did you source that Needle bearing?
in a local SKF bearing dealer
Is there a part number on it? I hope to dig this thread up in about year 5 of my Coupe ownership. It won't be complete till this is done.
Hi,

here you can find the references and specs of the "dequincey" design:

1u x hexagonal bolt M12 x 45mm - quality 8.8 or s.s.
1u x selfblocking nut M12 – 8.8 zinc plated


Needle Axial Bearing: brand SKF
2u x AXK 1730 from SKF d=17 D=30 e=2mm

Bearing Washers:
4u x AS 1730 from SKF d=17 D=30 e=1mm


Bushings:
2u x 12x14x15 material, brass


Flip washers:
2u x washer for M12 zincplated



Hope it helps.
 
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duane_sword

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My handbrake upgrade will be installed tomorrow .... Looking forward to a rattle-free future thanks to deQuincey.
 

Nicad

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I'll see if I can source those from the local purveyor of bearings. Good recipe!
 

duane_sword

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Installed! Works brilliantly! Thanks deQuincey. No rattle and shaking from my handbrake even at 100mph on the race track yesterday.... See my posting "E9 Driven" in the Photos section of the forum today.
 

deQuincey

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happy to know that you were successful !
yes it is a nice upgrade !
regards
 

Stefan

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paul cain's handbrake upgrade

All respect to paul cain for this simple and nice upgrade.
A lot of us did this upgrade early.
Are there more simple and useful improvements made by
paul cain?
 

deQuincey

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All respect to paul cain for this simple and nice upgrade.
A lot of us did this upgrade early.
Are there more simple and useful improvements made by
paul cain?
hi stefan,

probably you meant that this is NOT the paul cain upgrade, but an upgrade of the paul cain upgrade: the bronze bushings make the difference :)



thanks to paul cain idea this was possible !
 

deQuincey

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Hey DeQuincey - can I buy one of those kits? Paypal?

Thanks,

Rohan
hi rohan,

i am very busy now, but if you are patient enough, i can certainly produce a couple to help forum friends

i would prefer to prepare two or three sets simultaneously, cos i will have to order the components

not sure about the final price, but certainly i can check, i assume that each set can go for 25-30eur shipping inlcuded

just confirm your interest and give me a couple of days to check this again

regards
 
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