Sportster Handbrake woes

[iank]

The handbrake cable on my early 1997 factory built Sportster has just given up the ghost.

The vehicle has the early Ford rear setup with Ford Sierra disc calipers.
The existing cable is an Ford item and I have trawled through the "Firstline" online catalogue for every Ford model created however I cannot source one the correct length. My existing cable is one piece with an central cam plate. There is an plastic adjuster nut on the drivers side of the cable.
Existing length is 2120mm dead or 2110mm "bearing surface to bearing surface"

I have contacted Marlin direct but still await an reply.
Any clues anyone???

[CosworthCabrioLee]

Re: Sportster Handbrake woes

Hi Ian I have been through this on a cabrio when I converted from drums to discs and struggled to get the correct length cable. I sourced a rs2000 cable off a mk5 escort and shortened it on one side with a clevis from a DIY store. It is still in use now with no problems also bob jackson in Penrith used a simlair idea.
Speedy cables will make you a cable as they made them for marlin but need a length to make it too
If you want to call I can try to explain what I did in more detail
Regards
Lee

[CABRIOBOB]

Re: Sportster Handbrake woes

If I recall when I fitted a brake disc conversion to my Cabrio I used a handbrake cable for a Sierra with disc brakes but it was to long for the Cabrio, so I cut the cable/clevis off one end and got another clevis, fed the cable in to the new clevis and fitted a small cable screw nipple in to the new clevis prior to fitting it to the disc handbrake lever. Then pulled the inner cable through the clevis to the required length with the outer cable adjuster slackend right off then tightend the small nipple screw.

Give me a reply if want some pics, as I need to remove the wheels.

Cheers.....Bob

[iank]

Re: Sportster Handbrake woes

Hi Lee,
Many thanks for the reply. Did you have Sierra calipers on your Cabrio as I would need the clevis to fit the existing fork which is quite wide. How did you secure the clevis pin to the cable.
I have looked on the "Firstline" website and they list many Escort cables. Would you remember what year and engine size the cable was applicable to?

Kind Regards
Ian

[iank]

Re: Sportster Handbrake woes

Hi Bob,
Many thanks for the reply.
Lee has also kindly suggested a means of utilising a Ford cable and then modifying it to suit his Cabrio. Do you remember which model of Sierra and year the cable was from?
Can you recall what type of clevis pin you used and if you also had to modify the existing cable sleeving to the correct length?

I cannot quite envisage how the cable screw is attached to the cable and clevis pin so any photographs of this area would be of great assistance. I not intending to tackle the job until the weekend.

Many thanks
Ian

[CABRIOBOB]

Re: Sportster Handbrake woes

Ian

The clevis is 40mm long end to end and the slot is 6mm wide.
You can use electrical choco blocks wire screw nipples (cut in half if to long with 2 screws) once you have removed the plastic as in picture or even wire cable crimp ends, you will able to get from your local hadrware store.

I used a cable nipple screw and a crimp cable end and it was a tight fit in to the clevis but it works.

I think Lee put his inner cable through the cleveis and pulled it back used a small clamp shackle to fix it to the cable. see pic of shackle.
You may need to fit a small jubilee clip to the outer cable after you have fitted it through the caliper hole to help hold the cable from slipping back.
See attached pics as may help.

[CosworthCabrioLee]

Re: Sportster Handbrake woes

It was off a 1995 rs2000 as its shorter than the sierra one.

[iank]

Re: Sportster Handbrake woes

Bob,
Pictures are great. I can see how the cable is secured. I notice the clevis pin has an hinged closable shroud. This is also an great idea. Can you recall where you purchased this from?
Again, thanks for all your time and assistance. Its much appreciated.

[keith_h]

Re: Sportster Handbrake woes

I don't know if it helps or not but the handbrake on the YKC (Sierra GLS donor - disks all round) Roadster is the standard cable from a Sierra GLS with a short adaptor cable Unipart no. UGC GVC 2235 from a Fiesta (circa 1994). It has 5/16"dia. banjo connectors sweated on each end and they are 90deg offset from each other. The distance between hole centres is 6". The Ford part no. is either 650 27 46 or 650 72 46 (poor writing) It has a nylon block glued in position half way along it which has to be cut off.

In 2006 I paid £4.62 for a replacement

[CABRIOBOB]

Re: Sportster Handbrake woes

Bob,
Pictures are great. I can see how the cable is secured. I notice the clevis pin has an hinged closable shroud. This is also an great idea. Can you recall where you purchased this from?
Again, thanks for all your time and assistance. Its much appreciated.

Ian, I got the clevis from a local hadware shop ACE FIXINGS, you can get them on ebay also.

[dogoncrazy]

Re: Sportster Handbrake woes

Great British Sportscars [Kit Spares] do a shrtened cable for Sierra /disc brake cars .They don't specify length on their site only that it's suitable for their 'Zero'.Might be worth a call.

[iank]

Re: Sportster Handbrake woes

Hi Keith,
Thanks for the very detailed reply. I will do a search on the parts you have mentioned and see if they will be suitable or can be adapted to suit the Sportster rear discs. I will keep you updated on progress.

Thanks again

Ian

[iank]

Re: Sportster Handbrake woes

I had a look at the part from "Kit Spares" the other evening. I have sent an e-mail requesting more information but to date have not received an reply. They are also listing the part as out of stock. Typical!!
I have also contacted "Westfield Sportcars" as they also have a suitable cable. Again, waiting for reply.

Thanks for the info

Cheers
Ian

[keith_h]

Re: Sportster Handbrake woes

Hi Keith,
Thanks for the very detailed reply. I will do a search on the parts you have mentioned and see if they will be suitable or can be adapted to suit the Sportster rear discs. I will keep you updated on progress.

Thanks again

Ian

Hello Ian,

Those part numbers are for what is effectively a short approx. 6" link cable that works with the standard Ford rear brake cable (Unipart GVC2256 - for a Sierra GLS which has rear disk brakes) and takes a clevis pin both ends. One end attaches to the crescent shaped part on the brake cable and the other attaches to the modified handbrake bottom end. This will only be any good to you if the position of the clevis pin on the handbrake on the Sportster is the same distance away from the brake cable as it is on the Roadster (I suspect it might be).

Because the ground clearance on my Roadster is so small and the handbrake cable support bracket is the thing that gets whacked time and time again (God bless sleeping policemen), I treated myself to a spare handbrake cable from Unipart. If any or all of the above doesn't make sense let me knowand I will open up the packet and photograph it

[Mike]

Re: Sportster Handbrake woes

Ian

My understanding is the Sportster was developed from the Cabrio chassis, so your set up should be the same as a Cabrio with disc brakes. The manual simply says it will need shortening.
Buy a cheap new Sierra cable from your local motor factor, or off ebay, and then send it to Speedy cables for them to shorten it to your exact requirements.
Much quicker, and a job well done.

Mike