Amazon: Brake System Upgrade

[Oilline]

Indeed they do fit and that is what i have done

[classicswede]

Originally Posted by 940_Turbo

Why are you putting in an 1800 rear end? The axle needs modification to fit the 120 wagon rear suspension. The 240 axle has a far superior handbrake mechanism and is the right width, still needs modification of course.

The 1800 rear axleis teh correct width for teh amazon. The 240 axle is wider and would require different ofset wheels to fit.

[jimbo1593]

Yes the part numbers on the later stub axles is the same as the earlier stub axles so the later PCD hubs will fit.

[dheming]

Originally Posted by Oilline

Indeed they do fit and that is what i have done

Originally Posted by jimbo1593

Yes the part numbers on the later stub axles is the same as the earlier stub axles so the later PCD hubs will fit.

Thanks for the confirmation guys. Now I just gotta find an affordable pair of hubs.

I'm currently moving to a much nicer part of the Bay Area so this whole project is on hold for a couple weeks. New place has a two car garage though so it'll be back to business soon.

[telboyofpeckham]

Originally Posted by Ron Kwas

Derek;

compelled to comment that you do beautiful work!.

Not just an engineer but a fine artist to boot!

[dheming]

This project has been on the back burner since I moved and then started school in February. Last week I built a 25' 50A extension cord and installed a circuit breaker at my new place so I can finally weld again. This week is spring break for me so I can spend some serious time fabing.

Yesterday I layed out(which took me quite a while to visualize) and cut the arm with my jigsaw from 3/16" mild steel.






This shows the alignment of the arm to the body piece which has been cut for the next step which is forming a tapered, curved I-beam. I have one side ready to weld and curve tomorrow which I'll post more pics of. It's starting to look more like a brake arm.

[john h]

I always enjoy watching your work - very high standards

John

[dheming]

Got quite a bit done today so there'll be a batch of pics; Enjoy. This shows the arm tacked onto the body and marked for cutting. The top flat stock is one of the I-beam sides.




The arm is fully welded to the body here.






Here is the side piece tacked on.






Bending the 3/16" x 1" flat stock around the curve was the trickiest part. I used a blowtorch, the bench vise, a few C-clamps, and a BFH.






One side is fully welded now. The inside curve of the other side is going to be the hardest part to do by hand.

[red92s]

Nice work.

What happened at the "tip" of the arm? Needed to be just a bit longer?

[dheming]

Originally Posted by red92s

Nice work.

What happened at the "tip" of the arm? Needed to be just a bit longer?

Yeah, in hindsight I should have ordered wider flat stock to cut the arm from. I'm making this design up as I go so there are bound to be mistakes, which there has been a few. The Mk II brake arm will be that much better because of them though.


Here's a few pics from today. First up is the other I-beam side. This was much easier than expected to make. I clamped a 2" pipe scrap in the bench vise to use as a form, heated the strip with a blowtorch, and applied the BFH to curve it. The smaller radius was then done by clamping in vise and bending the last 1/2" or so more inwards. The jaws in the vise I used really dug into the surface a lot, something I don't want to repeat on the Mk II. Hopefully I'll have a proper bender by then.




All clamped together and new side tacked on.




Both sides fully root welded now(a bit blurry).