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Randy Pflanzer
Technology Professionals Consortium
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   What's New?
 
  02/01/13 - Reformatted web page.

 

Brake Lines

I spent a lot of time studying the installation of the brake lines because the instructions are not that helpful.  After looking through some pictures provided by Lakeway Cobra, I decided that the first thing to install is the rear hose that connects the frame to a solid mounting point on the rear end for the rear bake lines to branch.  I had to supply the mounting hardware from my bin of aircraft parts.

The bracket for the pan hard bar is the preferred location and provides a solid mounting point for the fitting.  I drilled through the bracket and installed a nut and washer on the bottom side.

The other end of the hose connects up to the frame in the lower left mounting bracket as pictures.  The C-clip holds it in place.

At this point, I am not running the brake line forward from this point until I fit the body.  I'm looking at options on where the line might go and I won't know what options I have until I fit the body.  I will likely finish up this when I am disassembling the frame before it goes to powder coating.

Next step is to mount the flexible lines that run from the brakes to the frame.  The kit comes with two 90 degree elbows and two 45 degree elbows.  I chose to install the 90 degree elbows in the rear calipers and the 45 degree elbows in the front calipers.  I routed the hose as shown in the picture above.  So that the hose would not rub against the rear axle housing, I slid on a piece of the shrink tubing to provide a rubber buffer.  The end of the hose connects up to fittings that slip into the mounting bracket on the frame.  It is held in place with a C-clip that you have to purchase.  Again, why these suppliers don't give you the hardware you need just escapes me.  BTW, you need 5/8" C-clips.  I found them at Ace Hardware in their Custom Cobra parts isle.

From there, I installed the hard line.  When you make these lines, you need to buy a special flaring tool that puts a double flare on the line.  I picked one up at Sears.  Others have had problems with these inexpensive tools but mine worked great.  I found the job a lot easier if I put the handle of the tool in a vise.  That frees up both hands to do the flaring.

I routed the other brake line to follow the contour of the rear end housing.

UPDATE:  After properly locating the rear-end in the frame, I found that the shock interfered with the fuel line.  This meant that the mounting tabs needed to be moved to the front of the 4-link bracket.  Rather than try and cut and re-weld the existing tabs, I just welded a fender washer to the bracket.  Once I remove the parts for final paint, I'll cut off the old bracket and shape the new on a little with my Dremel.

Here's a picture of how I re-routed the fuel lines to use the new bracket.

That made it a straight shot over to the right brake.

UPDATE:  The brake line bracket was moved on this side as well to the front of the 4-link bracket and the fuel line re-routed.

On the front caliper, I installed the 45 degree elbow and routed the hose as shown.

I chose to run the line over to the right front brake by clamping it to the steering rack.  All the other installs I've seen require these elaborate bends to follow the frame and then the cross member.  I found my method to be simple, straight, and easy to do.  I'm sure someone will point out to me why this is a bad idea so until then, this is the way I intend to do it.  The kit comes with two brass elbows.  One has three flare fittings and it is used above to connect up the two front brakes.  The other elbow has a two flare fitting and a pipe fitting.  That is used for a brake pressure switch, if you are using one.

UPDATE:  After trial fitting the body, I decided to run the fuel and brake lines alongside the emergency brake bracket instead of in the driveline tunnel.  I took the tab for the rear brakes that was welded to the cross member, cut it off, and re-welded it here.

As you can see here, the flexible brake line now runs up underneath the tunnel rather than through it.  I think this is much safer.  It does mean that if the brake line leaks, getting to this fitting is going to be much harder.

I am not running the brake line forward just yet until I run the fuel line.  That work begins on the next page.