I thought that I would start on the e-brake installation, although it’s typically done a bit later in the build. The handbrake mechanism, itself, is relatively straightforward to put together— it’s a simple ratcheting mechanism with a spring release. Here are the parts:
I coated the bare metal parts with Rustoleum high gloss enamel. It’s pretty tough and is easier to repair than powdercoating. The photo below is of the assembled handle on the chassis.
The main issue in the installation was the interference of the cockpit aluminum with the handle as the handle would go to the released position (as above). The forums have several suggestions for solving the interference issue: reversing some of the bolts and elongating the attachment holes to allow the handle to rotate toward the PS. I did both of those things and they only helped marginally. A particular problem is the carriage bolt head in the lower right of the mechanism— the cutout in the Al just isn’t large enough:
The outline in the above photo is for the ‘boot’ that goes around the e-brake mechanism. I decided to enlarge the cutout in certain places but didn’t want to got outside of that line. The result of the modified cutout is that the handle can rotate more to the PS giving enough clearance for unimpeded handle movement and space for insulation and carpeting under the handle. I plan to put a ‘patch panel’ over some of the cutout to the rear of the mechanism that will be under the boot.
My next modification of the e-brake system is to change the routing of the cables. F5 has the cable go under the 4” crosse tube but I don’t like that configuration at is has the potential of having the cable damaged by road debris. Several of the forum members, e.g., page 170 of the following thread:
http://thefactoryfiveforum.com/showthread.php?18591-EdwardBs-Mk4-8674-20th-Anniversary-Build/page5&highlight=20th+anniversary+build
have created a different routing using Lokar cable clevises and a set of pulleys. I’m going to take that route and will start on that after the holidays.