Handbrake cables and fitting

 Well, last weekend was a bust due to much higher priorities (more on that later), but hopefully today I'll be able to get started on the handbrake cables. 

The first thing I want to consider is how tight the curve can be on the rear cables. On my car I've mounted the calipers backwards, so instead of routing the cable directly forwards, mine have to loop round. I also have the 'option' of mounting the calipers upside down. While this does cause headaches for bleeding, it may also help the routing of the cables. Whichever way round the brake flexi will always go up, which is easy. The handbrake cable has a mounting bracket that changes the angle depending on orientiation.

I guess the first thing I need to do is try both ways up and see which one gives me the best cable routing without rubbing on the chassis. Then the next question is how tight those cables can bend. This picture suggests they can bend quite sharply;

This appears to be a complete U turn in the length of the lower wishbones, using the standard bracket to fix it on the diff bracket. This would probably be tighter than I need it, but it does mean I have a fair bit of flexibility in the mount. 

The first step is now done. I've replaced the angle fixing brackets that were on the cables with straight brackets, and welded corresponding brackets to the chassis just behind the diff. The cables will route from there to the transmission tunnel, where they will fix into a mounting plate. That's the next step, to create a mounting plate across the tunnel. The cables are intended to clip very similar to flexi pipes, so I've ordered a couple more spring clips. Hopefully I'll get to cutting the brackets once the first step has cooled down.

(Several days later...)

The rest of the handbrake wasn't too painful in the end. Apart from a full week of trying to order some handbrake cable (how can any seller think bungee cord is the same as handbrake cable?!!), I finally managed to figure out the other end. First, a trial fit;

This bracket was the first design, but the handbrake cables are existing too high and rubbing against the chassis. This had to be dropped an inch, to this;

This is the final fit, all welded up with the balance bar in place. This will work fine, so the next part is the front section. It needs to be adjustable, so I spent a while figuring out how to drill through a threaded rod to get this;

Along with a cable clamp at the end, and a nut on the thread, this is my adjustment mechanism;

But at this point it occurred to me that I need the bodywork in place to figure out where the handbrake can go. There's a few places for it to go but it needs to be usable. So for now this is the end of the handbrake. Given that it's two holes and two bolts to fix it in place it shouldn't be too much work.

Next job, seats...