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Need advice on how to fix this one.

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Jim_Gruber

Jim_Gruber

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I noticed an issue with the E-Brake Mounting Flange on Bugsy's 1/4 Elliptic Dizzy. I am surmising the eBrake mounting piece got bumped while the dizzy was out of the car for 30+ years and in storage. There is a triangular piece cracked out of the aluminum flange. Looking for advice on how best to fix. The E-Brake pivot point is in one of the boxes that came with Bugsy I think, so at this point I do not know it's condition. Here are my thoughts on how to fix this one.

1) Drill an identical hole on the opposite side and swap e-Brake rods. This seems like the simplest fix but I do not know if this is possible.

2) smooth out the jagged edge and weld in an aluminum piece and redrill the hole - Since I cannot weld aluminum with equipment I have and do not own a TIG this doesn't seem possible although I have a neighbor with a TIG, not sure if he is set up to
weld aluminum.

3) Add a reinforcement plate under the flange, through bolted and use spacers to raise pivot point back up to the correct height in some fashion. My first thought but I don't know what sort of clearance issues are required for the e-Brake pivot Point.

Some thoughts gentlemen on how best to fix?

PS the other alternative is the find a 3.9 Pumpkin and pop it in place. 2015 04 25 Cracked E Brake Mounting Flange.jpg
 
Can you run a flange off one of the pumpkin bolts ?
 
That broken hole that I see on the housing is not for the e-brake pivot. It is the mounting location the the tee that distributes the main rear brake line to each rear wheel cylinder. Just drill another hole far enough away that another piece won't break off. You could probably even relocate it on the opposite side if you are making up your own lines anyway.
 
What he said and you can MIG aluminum but I'd just drill another hole.
 
Cool, I thought this was for the Emergency Brake. A much simpler fix. Thanks guys.
 
Jim,
Good advice from everyone. I would just use two big washers on either side of that flange to hold the brake hydraulic union in place.
Rut
 
Rut said:
Jim,
Good advice from everyone. I would just use two big washers on either side of that flange to hold the brake hydraulic union in place.
Rut
Click to expand...

I'm with Rut....all you need that mount for is to stop vibration.

Kurt.
 
It's on the list when I get to working on the diff. For now need to get Bugsy on the rotisserie.
 
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