Handbrake Mount

Posted: 17th September 2017 by asteriskr in 106 Rallye S1 16v
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So when I had the white 16v Rallye caged and the same tunnel reinforcement plate removed, the MOT station failed the car because the mounting for the handbrake was then too flimsy afterwards. To remedy that I welded a plate on around the handbrake mounting points which kept the testers happy, but was no good because then to fit the handbrake I needed to fit an extra bit where the tunnel changes profile towards the back of the car. It did the job but looked a bit piece meal.

Based on this experience I thought that I would do something different this time. So cardboard template led to this being cut out of 3mm sheet. Centre line determined and a lesson learned in getting the plate the right way around. This is clearly the wrong way around…

Hydraulic Handbrake Mounting

Before that could go in, the original tunnel reinforcement plate was cut up to release this bit, which is what the handbrake gasket mounts into and gives the positions for the mountings. The standard mountings are 6mm rectangular blocks tapped out to M8, but I was missing one so I pressed out the other one and welded on some nuts onto thick washers giving me this:

Hydraulic Handbrake Mounting

Bit of fettling for shape and welded in:

Hydraulic Handbrake Mounting

Top plate shaped to fit the handbrake mounting points and the other end shaped to the change in profile of the tunnel. Back mounting points for the hydraulic handbrake get crush tubes. Decided to make it a little bit more interesting with a relieved bit under the hydraulic handbrake that matches up with the holes drilled in the base. Lined that cut out to stop crap getting under the plate…

Hydraulic Handbrake Mounting

Welded in

Hydraulic Handbrake Mounting

Everything fits.

Hydraulic Handbrake Mounting