[doc] Handbrake caliper failure and repair.

["Phill Wright" <psw@xxxxxxxx>]

Hi all.

this may be of use to someone else at some point :-)

While assisting in the removal of Claire's wheels on Flopsy recently 
(for the wheel-refurb), it was noticed that one of the rear wheels 
was freshly scored inside. Investigation showed the cause was the 
too of the handbrake cable fixing was scaping the inside of the rim! 
(handbrake was working so it had gone un-noticed until wheel was 
removed). The handbrake arm had vertical movement which it should 
not have and it was sloppy at the pivot end.
I removed the handbrake section from the top of the caliper and when 
it was dismantled it was obvious what the problem was. The pivot 
block (for want of a better term) had sheared off the caliper arm - 
the block is effectively rivited into place.
Repairing this is not to difficult (when you have a mate with a 
decent workshop). There's a link to some pics below ...
I drilled and tapped the block to 6.0mm (5mm drill size), drilled 
out the sheared stud from the caliper arm and although the hole is 
chamfered it needed countersinking to the right angle for the new 
fixing screw (note in the pics, the red stuff is threadlock, guess 
who forgot to take pictures and had to dismantle it again :-)  )
The whole thing was then cleaned up and reassembled with some 
permanent threadlock. The screw is a hardended one btw. The repaired 
unit works a treat.

http://www.fab1.net/flopsy/handbrake-caliper.jpg

Cheers

PhillW
DOC233
VIN 6772 sorbet (not schnorbitz) 







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