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Mk5 Golf R32 , black 3 door 2006
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Discussion Starter · #321 ·
And the next little curve. These are prototype electric 4 pot rear handbrake callipers . 4x28mm pistons and 140mm centre radial mount so a direct swap for my existing rear mechanical handbrake callipers. And the snag: no controller and the VAG one is a non starter as it is integrated into the ABS , so transplanting one of those into an R32 would be , err, tricky . Plan ‘b’ is to develop one form an aftermarket controller . Watch this space . Automotive tire Automotive exterior Automotive wheel system Bumper Gas
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Discussion Starter · #323 ·
They come fitted as standard on BBS Ch-R rims and are stainless steel They do a great job unless the driver is a complete and utter Pratt and gives a kerb not a kiss bit a really good head butt . My defence is that I did not even see the kerb as I made my exit . Oh.Forgot . Not seeing something is no defence .
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Ouch on the wheels. Good to hear about MOT. As for the rear brakes, is it a simple 12v on/off? If i am not mistaken, there are a couple of blanks in the center console, get a button for that? Alternatively, use the signal from the existing handbrake switch? It would still provide the appropriate signal to the abs that was too. Trying to remember but i believe when the brake is disengaged, that switch is open.
 

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Discussion Starter · #325 ·
Hi. Nowhere near that simple. First , the design needs to take note of the stalling current and then ramp down that current at a set interval after stalling ( say 1 second ) so that the pads are fully pressed onto the rotor. Then , on disengagement, the pads need to be retracted by a set amount ( ie the motor needs to wind back by a set number of rotations . ) At pad change , there needs to be a protocol that fully retracts the piston . And to ice the cake , the hydraulic pistons are not actuated by the motor: the latter actuates a centrally mounted single piston , which means that that the hydraulic circuit is not in any way integrated into the parking brake, so having this parking brake operated via the ABS circuit is of no use or value .
Stalling current and current sensing are not too bad with a few transistors and a MOSFET on a nice big heat sink . Timer delay using a standard timer chip. The other bits are causing a bit more head scratching, hence the idea of using an aftermarket controller( one or two designs available from places in the States , Pantera electronics being one of them . ) That one is designed for the Brembo /Tesla calliper which has a different drive motor ( I have the TRW one ) but that alteration is easy as per the above
Anyway , nothing quite like taking something that works, removing it and putting in its place something that doesn’t . 😀😀😀
 

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Sweet jesus that seems painful to sort, just stick with the cables lol!

Edit: for what it's worth, i suspect nfg ebrake is what caused the passat to fall into my hands. There was what was clearly a replacemet module in the car but equally clear was it was the wrong one as it wouldn't program properly. This is what caused the driveability issues (traction conteol interfereing with acceleration) and (when i recived it) non functioning haldex. I could get the engine to run well with it disconnected and haldex would work with it partially programmed.

Basically, it's up to you but i can't see how it's worth the effort. And even if you get it working, what are you gonna do about the handle in the cabin?
 

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Discussion Starter · #327 ·
I know. But I have these bad boy electric jobs as a prototype development job at no real cost for the callipers . But I need to come up with the electronics . If I can get them to work, they will be an improvement on my existing handbrake , which would be absolutely fine on a lighter car, but at 1600kg on a 15% slope , the net torque applied by the weight on the rotor exceeds the torque that can be developed by the clamping forces and friction on the rotor. On a car a few 100kg lighter, they would be absolutely fine , and as rear brakes now they are brilliant , so I am not desperate to change them by tomorrow morning !
 

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Yep, my R32 is still collecting dust, nothing new at the moment.

Something I've catched. You mentioned ALU front wheel hub housings, which are apparently different dimensions and longer control arms are needed. What about combinating these on MK5 with ALU lower control arms from Passat B6? Considered that option? :unsure: I believe the alignment would in that case, be perfect.

I have both the upgrades ready for my car but didn't really thought that ALU housings are in any case different than alloy ones (measures wise).
 

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Discussion Starter · #332 ·
Morning,
The hubs are from the Passat . I already had the Superpro alloy arms which were correct length wise. The steering arms needed to be lengthened by 15mm but otherwise everything was fine. And yes, the Passat lower arms with the hubs will also work, but just beware of the steering .
 

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Discussion Starter · #333 ·
Handbrake update . The controller lives, works and is now in a little cobbled together box. Away on a weeks holiday then time to fit the calipers , electrics and the hope .
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Discussion Starter · #334 ·
Well.Holiday over. Then a week underneath my sons Mazda MX5. Then a dose of Covid , then back to handbrake controller. Sorted out all the switch wiring , then mocked it up in the car but with the callipers just sitting in the boot , press the button , left hand calliper activated and the driver chip for the RHS calliper spat out its dummy . How could I tell? Because the little sod looked me in the eye and then caught fire . I took the hint and switched off. Slight pause whilst I sort this one out . And in the meantime , got a very slight misfire so ordered and fitted some new plugs and coils ( TPS o.e stuff) . Absolutely transformed the car . I should have mad a video of the Lund coin standing on its edge on the inlet manifold with the engine ticking over . Well done VW . Still have all the coolant hoses, clips, pipes and thermostat to change but not today . A tad warm
 
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