DIY - HandBrake - Rally Style - 100% Aluminum Handcrafted - G27

27
Venezuela
Barcelona
D4rkSn4keE3ter
Hi everyone, this is my first tread posted in this forum, and this is my project in its final stage, this project started in january 2012 and ended in december 2012, lot of work in my spare time, hope you like it.

This project has two version, the first one was whit the polycarbonate lever, and it was a failure because the lever bend sideways so i had to put it aside, and start whit the aluminum, my first attempt whit this material and very grateful as it is, it allow me to make a beautiful, smooth durable handbrake.

I aim for the perfect Drift handbrake, and ME a novice, beginner, amateur drifter :D , i have to make of those i said.

The idea stared whit GTPlaner sim forum, and the awesome rig you guys post here, and the idea became paper and so on....

This is the replica i aimed.


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i just copy the style and shape, then i start to make the patterns in card cardboard.

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Then the lever, as i said, i drop the idea because bended sideways, and the hard part is that took me more time and effort but the aluminum lever, but ill show you anyways.

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I sand and bonded the layers, then shaped whit the pattern.

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I add this reinforcement.

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And craft this beautiful grip.

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Well, when i realize the this lever wont work i step aside the project for months, the i start whit the aluminum and unfortunately i don't have much footage of the progress i made, i apologize for that.

Here is the aluminum lever.


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I made the hole whit wood hole saw drill bits :) (i know they work)

And the base.

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Aluminum pipes for the lever grip and the spring housing. and made aluminum finishing touch whit sanding paper to get it shiny.

I use a thick spring to add realism to the lever trow, i can change the spring for a harder one or add ring spacers between the spring and bar, done whit the hardware.

the electric part, its simple one micro switch on the bottom of the lever wired to the G27 circuit board using cable from an old spare phone, (It can be remove) to the (pillow) A foam whit 2 layer of polycarbonate that absorb the over trow, and give and smooth ending to the lever, i torch (Spiral) the blue wire using a round bar and an a drill.
The blue wire gives the (Where do you buy it?) many people don't believe that i build it myself :ouch:

Anyway here is the Handbrake in its final stage, hope you like it.


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Thanks to chillicoke for the guidance on how to wire the G27 electric board,
to my friends in the boatyard for lend me their tools.

Now the question is: how do i wire this baby to my new T500RS?

Hey here is my pedal set, whit the handcrafted foot rest (dead pedal) i made take a look

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Comment and rate, questions are very welcome​
 
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Outstanding, I need one of these! All I can say is wow! Not to mention your very tidy pedal box!
 
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thanks m8! i appreciate, its been one year since i buy my G27, and now i order for the t500rs, about to arrive, is there a tutorial to wire a DIY handbreak out there?
 
amazing!, how did you wire it to the handbrake you made? im seeing phone cords? (newb at this) and dont really understand your explanation, haha sorry.

But it looks very very clean and slick and love the deadpedal.
 
amazing!, how did you wire it to the handbrake you made? im seeing phone cords? (newb at this) and dont really understand your explanation, haha sorry.

But it looks very very clean and slick and love the deadpedal.

you need to open the G27 shifter and solder the wires tho the circuit board, in my case i use switch and installed at the bottom of the lever, when i pull the lever the button its pressed by the pillow, (its like pressing a single button in your g27 shifter)
 
you need to open the G27 shifter and solder the wires tho the circuit board, in my case i use switch and installed at the bottom of the lever, when i pull the lever the button its pressed by the pillow, (its like pressing a single button in your g27 shifter)

What kind of switch did you use? Thanks again!
 
Wow, well done! I've been wanting to make one for a while but nothing close to this nice! I think I speak for everyone when I say please let us know if you decide to make more of these!
 
Hi @ all !

Ive got a DIY handbrake too , wired in my t500 rs ,you can See in in my First thread ! If you want , i can Tell you how to wire this easily on The t500 ! If you Looked at my pics , comments are welcome !
Greetings from Germany
 
Hi @ all !

Ive got a DIY handbrake too , wired in my t500 rs ,you can See in in my First thread ! If you want , i can Tell you how to wire this easily on The t500 ! If you Looked at my pics , comments are welcome !
Greetings from Germany

hey i did see em, good looking handbrake you have there, can you adjust the hydraulic pressure?

how do you wire it to the t500rs?
 
Hey ! The pressure depends on The brake Fluid , more Fluid , more pressure , less Fluid , less pressure ! I just opend The bottom of my t500 wirh that 7 screws and put The cable on The R3 Button ! Welding is Not The right word ! Its löten in German , but i guess you know what i mean ;-) ! Its The easiest Way imo !
 
Yeah , Feel Free to ask if you got any question ! Have Fun with your t500 , i had a Lot of wheels , including The expensive fanatec stuff ! But The thrustmasters Kicks everthings Butts !
 
Great stuff DarkSnakeEater:tup:

You just inspired me into building my own DIY rallystyle handbrake. :)

Plans are being made as we speak and i already made the hand grip this afternoon.

I will use a 80/20 profile as base, so i will be easier to mount it to my rig.

Did you also mount some damping material in the spring housing?
 
Did you also mount some damping material in the spring housing?

i didn't, its not necessarily i think, when you pull the lever the you release it gently, it don't take much time.

i test the handbrake racing in gymkhana dirt3 ps3, you know how demanding hand-braking is gymkhana, got platinums whit it.
 
Great work, but those handbrakes are cheap as chips anyway....would it not have been easier to buy one and add a spring and the switch?
 
Great work, but those handbrakes are cheap as chips anyway....would it not have been easier to buy one and add a spring and the switch?

Would you be so kind and give me some links of webshops that sell those handbrakes you are talking about?

I just might buy one instead of making one my self.
 
Yep ebay is where I've seen them. £50 ish, which isn't a lot really considering that a DIY job needs materials and fixings etc to be bought. Depends what you're budget for such projects is though I suppose....
 
Great work, but those handbrakes are cheap as chips anyway....would it not have been easier to buy one and add a spring and the switch?

Not for me, US Dollars are restricted in some ways, i only can buy products (online) outside my country (Venezuela) whit $400 annually, i rater buy more important things whit it.

in fact the build of this handbrake was $0 because i got the materials and tools from the boatyard i work.

everyone has his own reasons is it?
 
Not for me, US Dollars are restricted in some ways, i only can buy products (online) outside my country (Venezuela) whit $400 annually, i rater buy more important things whit it.

I know where you are coming from DarkSnakeEater, there are quite a few countries where imported goods cost quite a bit more than in the EU or North America.

The guys I know in Brazil pay around double the price that we pay in USA for sim gear by the time shipping and customs charges are added up. :crazy:

Like Dark Snake Eater, i have all the materials needed already.

Make one for me too! Lol, just kidding, I am sure what you come up will be an awesome addition to your rig! :sly:
 
Very nice work :)
I'm building a DIY handbrake at the moment myself.
But your solution is great for my 2nd rig, because i still have another G25 ;)
Thanks for sharing and keep it up!
 
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