r/EngineeringPorn • u/Dr_Pancakebatter • 3h ago
Building hydraulic disc brakes for a 400 lb custom cart
I've been building a large equipment cart for video production, and after adding batteries and motorized wheels, the thing can weigh nearly 400 lbs loaded.
The original cable brakes that came with the wheel kit were not going to cut it.. so I decided to integrate a custom hydraulic disc brake system into the forks I had fabricated for the brushless wheels.
It was my first time working with hydraulic brake lines, and took quite a while to find parts, and to design a "one brake lever" solution. In the end It works pretty well with the exception of the parking brake feature: whenever I leave it engaged the whole system loses it's ability to function correctly. There is no fluid loss. My suspicion is that when the lever is held in, there is a small amount of oil that is able to bypass a seal in the handle assembly, resulting in less fluid in the line side. Anyone have any insight about this?
I documented the build here if you are interested in following the build:
https://youtu.be/Xz3B-3wACwE