Hi Spec Handbrake - is there a better way

[Rob P]

Just been advised that the car has failed it's MOT on the Handbrake which isn't a real surprise as it is so hit or miss it's a joke
Car has Hi Spec Brakes front and rear and whilst I have tried to adjust the Handbrake I can manage to get it to operate nicely providing you use two hands to complete five clicks and it holds remarkably well, however trying to operate with one hand only gets you four clicks and a child of five could push it away

Is there any magic formulae to getting these to work or are all of the rumours I've seen on here true that they are just complete and utter rubbish, looking at a Spot caliper but agan not sure these are any better, anyone any guidance that I can follow up on? I have reviewed most of the posts brought up by searching Hi Spec and Handbrake and nothing really suggests any alternative so hence my desperate pleas on here.

I already have the longer levers from a previous group buy installed and these still don't give enough purchase to get through the test, I think it topped out at 9%, 12% gets a pass I believe so once I have the car back I'll have another play but would be useful to have some alternative suggestions to follow up on

Hellpppppp

[Enright]

I'm only chucking ideas around of what I'm familiar with at the moment, but I wonder how feasible it might be to adapt something off the shelf for use on the Elan?
I've done quite a bit of work on MG/Rover cars in recent years, including rear brake to disc conversions, and upgrades in brake size, all using standard parts from other variants in the range.
This was on MG ZR's (Rover 25's) and MG ZS's (Rover 45's). These cars are 2-300kg heavier than the Elan, and the higher power models produce 160-180bhp so the components should be up to the job, and the layout is at least similar.
It would come down to how adaptable the connections and mountings are in order to provide the right operation and offsets.
There are tons of them in scrapyards which should mean plentiful cheap supply for years.
Proportioning valves might be a consideration to get the balance right, but I think I've still got a set of rear discs and calipers knocking about, and need to free up the ones on my original Elan which has seized while standing for so long, so I could at least do a back to back comparison fairly soon.

[DABgp]

Hellpppppp

I assume the PNM's own callipers were developed as an alternative to these? More than you wanted to spend Rob?

[Rob P]

Hellpppppp

I assume the PNM's own callipers were developed as an alternative to these? More than you wanted to spend Rob?

Yep my cash is being saved for another vehicle option so shelling out on another set of calipers isn't on the cards, looking at the set up here to my mind the way the cable is routed back on itself is part of the issue. Once the car is back (i.e. Tonight) I'm going to have a look at how I can arrange the cable to avoid this. Looking at most other cable operations for handbrakes the Caliper is rearward of the wheel not like the Lotus which has the caliper forward of the wheel.

On the Mini the cable is pretty much a straight pull with very little in the way of curvature in the cable routing which has to be better, might be an option to have a play with a lever system if I can work out a suitable mounting point.

10 days to get this sorted before the need for repaying for a second MOT kicks in

[lotusgirlmarie]

I hate to play devils advocate but, go back to stock for your MOT. Pass the test then bugger about with the brakes. Especially in the time frame alotted. Would be your best option I'm afraid.

A spot caliper would work. A new braket would need to be fabricated. Was looking into this awhile back and even purchased two different types of handbrake calipers. I chose a different option in the end and it's what I'm moving forward with now. I'm going with lotus elise brembo rear calipers. They'll mate nicely with my brembo fronts and I'll use larger ventilated discs to even out the bias. Was previously kicking around the idea of VW golf rear calipers as well. Bigger piston than stock to balance the fronts.

[GeoffSmith]

Was previously kicking around the idea of VW golf rear calipers as well.

That's what the PNM kit is based on. Can't wait for my originals to pack up and put them on.

[RayD]

Rob,

You'll need to do some work later, but just to get it through the test take the glaze off the rear pads and discs with medium "sand paper" being sure to keep everything flat. Oil any pivot points you can get to and slide the plastic handle on the handbrake lever forward as much as you can without interfering with the function on the button ... all of which will make more than 3% difference.

Ray

[Rob P]

Thanks for the responses

Lotusgirlmarie - Sadly I cannot return to stock as I bought the car with these calipers already in situ so will need to work with these for now.

Ray - looks like the jobs you highlighted wil be the first things on the list for this weekend as I'm heading out for customer meeting for the rest of this week so the car will be left until then. Lets hope those small pieces of work will be sufficient to get it a pass.

Are there any posts on the options you mentioned for the replacements that people were looking into? I did a search this afternoon but couldn't find anything related to this subject.

[RayD]

Try to use the brakes as little as possible between de-glazing and the MOT Rob and post some pictures of the mechanism to remind us what they look like.

Ray

[rip]

Was previously kicking around the idea of VW golf rear calipers as well.

That's what the PNM kit is based on. Can't wait for my originals to pack up and put them on.

My originals were useless...so were the Dormans I replaced them with.

I have now replaced them with PNMs. Half the handbrake travel & it actually holds.

As for the HiSpecs.. Can you make a longer lever for them? A bit more leverage may help you get the required bind with 1 hand.
In the short term, I would follow Ray's procedure.

[lotusgirlmarie]

The issue with the high specs is in the design. They attempt to use the risidual hydraulic fluid to actuate the pistons. Fine in theory, not in actuality. It's why that design is illegal on road going cars in the US. Given that some modern cars have skirted this and achieved DOT exemptions. I like to err on the side of caution when it comes to brakes though and want a mechanical/physical connection alternative.

[muley]

I have the PNM rear kit fitted - with the Golf Mk IV calipers.

I was working on the car a few weeks back and found the offside (driver side in the UK) wheel was turning freely with the handbrake full on.

Investigation showed the angle the cable came out of the bracket towards the lever was too acute and it was binding before fully operating the lever. To fix it I re-routed the cable UNDER the exhaust. I had to fix the cable to the lower wishbone with cable ties to stop it getting burnt.

Last week it passed the MOT. It was a bit disappointing to find that on paper the rear brakes were much the same as last year. I didn't record the exact numbers.

I had raised the problem of the angle of the cable with PNM and they weren't particularly helpful - just a couple of tips on how +I+ could modify the bracket...

Jim

[Rob P]

Thanks for all the feedback, took time to review this yesterday and after much soul searching and head scratching the outcome was to further extend the lever arm and lo and behold we now have a workng Handbrake which is able to be applied without needing arms that have had fifteen months gym work, four clicks and the car now holds on the sloping driveway which should get it through the MOT.

Trouble is test drive revealed a new oil leak, spraying oil from behind the engine, couldn't see where it is coming from but looks like it is only when driving as fired up the engine whilst on axle stnads and could see any leaks, looks like the car will be back in the garage next week so they can get it up on the ramps and get it sorted

Starting to lose patience with the car now

[Enright]

There's not much round the back TO leak, other than the oil filter. It's not worked its way a bit loose has it?

[epipete]

Starting to lose patience with the car now

Don't give up yet, I feel your frustrations, but 12months ago you told us:

Re: I hang my head in shame. Miles on Elan.
I've done 1,200 since I picked mine up from Paul Watkins, can't stop driving it, it's just such good fun. Plus most of those miles have been with the top down

[dapinky]

There's not much round the back TO leak, other than the oil filter. It's not worked its way a bit loose has it?

The only other thing I can think of is the oil pressure sender switch - quite inaccessible, but easy with the prongeron off!

[Rob P]

Starting to lose patience with the car now

Don't give up yet, I feel your frustrations, but 12months ago you told us:

Re: I hang my head in shame. Miles on Elan.
I've done 1,200 since I picked mine up from Paul Watkins, can't stop driving it, it's just such good fun. Plus most of those miles have been with the top down

Thanks for the reminder, don't get me wrong when the car is running it is great fun and I am making changes to the car to make it my own. It is here for keeps but the frustration recently is starting to take it's toll on my patience.
Will be checking the Oil filter later this evening if the weather holds to check it is still tight, funny enough no oil on the drive after running the engine for ten minutes at the weekend, can't take it outuntil it gets a revisit fr the MOT and then it will get some serious miles on it

[Rob P]

There's not much round the back TO leak, other than the oil filter. It's not worked its way a bit loose has it?

The only other thing I can think of is the oil pressure sender switch - quite inaccessible, but easy with the prongeron off!

Cheers Dave, this was checked a while ago as it wasn't working when I picked the car up from Paul and proved to be just a bad connection, another thing to check once I have checked out the oil filter.

[Rob P]

There's not much round the back TO leak, other than the oil filter. It's not worked its way a bit loose has it?

Checked the Oil Filter which is sound, however sat there a while looking at the spray of oil and then noticed the CV Boot was split, didn't think any further as I assumed these were full of Grease. Silly me forgot this is a Lotus so after searching on the forum came across one of enrights posts which had the following Quote

""They dont use standard CV grease - instead it's a sort of thick oil so if you get a split boot it's a right git of a job because the whole lot needs to be re-assembled vertically to do it properly""

which was enough to confirm that this was the issue, question now is can you still get the CV Boots ?? Feeling a bit better until I find out ofcourse that these are obsolete and then I'll no doubt hit the depths of dispair again

I suppose it all a learning curve

[dapinky]

Rob,

First the good news..... All parts easily (and cheaply!) availlable from here - ignore the fact that they are listed for the Elise - they are a 'standard' part and I have fitted them on mine

If you like lots of reading, have a look at this post on H-J's thread....

....it gives 2 links to even more reading of my long-winded writing!!!