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Dave Williams (sleepydawg) > A closer view of the bias bar assembly with "major system failure". I tried all variations of the pull rod hole locations to check for binding. There are no problems, they all look like a variation of this picture.
Dave Williams (sleepydawg) > Here's the whole reason for this design. I've dropped one of the clevis pins out of the bias bar, as if I've had a complete failure in one of braking systems, front or rear. You can see how the pins rotate to still be an inline pull for the remaining master cylinder. It's hard to see here, but the brake pedal has lost only about 1/2" or so of travel. While it might be a bit scary, the remaining system should be able to safely stop the kart.
Dave Williams (sleepydawg) > Another view of the mocked-up assembly, this time looking forward.
Dave Williams (sleepydawg) > Likewise, the brake pull rod is fabricated out of a piece of the same 1/4" CRS rod. Again, the threaded ends are cut on the lathe. I REALLY don't like using common all-thread for this part.
Dave Williams (sleepydawg) > Whew! After all that work, here's the master cylinder and bias bar assembly mocked up as it will be run. Note that I've got to do some painting of the bare parts and attend to little things like brake plumbing. You can see how I fabricated the brake dog bones (dawg bones?) out of two clevis yokes. The yokes are tied together with a hunk of 1/4"-28 threaded rod and some jam nuts. I cut threads into a piece of 1/4" CRS rod using the lathe for that part - I don't like using common all-thread for this, as it tends to be made out of low-grade or weak steel. My local hardware store occasionally has a few pieces of hardened all-thread rod, but they were out this time around.
Dave Williams (sleepydawg) > Here's all six freshly cleaned up clevis pins after a bit of grinding and thread cutting with the die to fix the first thread. For reference, there's the aircraft-style clevis pin again.
Dave Williams (sleepydawg) > Well, it's real hard to catch with the camera when you're trying to turn the lathe cross slide with one hand and aim/shoot the camera with the other one, but the shank of the bolt just went flying that-a-way...
Dave Williams (sleepydawg) > Cutoff tool in action on the lathe. A good HSS tool has no problem with a hardened grade 8 bolt.
Dave Williams (sleepydawg) > I've drilled the bolts for the safety wire/cotter pin backup. You can just see the tip of the hole peeking out at the nut here. I've got it mounted in the three-jaw chuck on my South Bend 9" lathe, in preparation to cut them to length.
A closer view of the bias bar assembly with "major system failure". I tried all variations of the pull rod hole locations to check for binding. There are no problems, they all look like a variation of this picture.
Dave Williams (sleepydawg) > A closer view of the bias bar assembly with "major system failure". I tried all variations of the pull rod hole locations to check for binding. There are no problems, they all look like a variation of this picture.
A closer view of the bias bar assembly with "major system failure". I tried all variations of the pull rod hole locations to check for binding. There are no problems, they all look like a variation of this picture.
See photo in gallery
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