jamiehamy 0 Posted January 18, 2015 Hi all, I had a problem with the Rado last week - pulled the handbrake on and it just 'gave', and didn't apply. I took off the tunnel plastics to reveal the source of the problem - the forward attaching bolt for the handbrake had pulled through the attaching plate. I was worried that I'd pulled a hole through the tunnel, but maybe this plate has been designed to be the part that goes? I don't generally pull the handbrake on too tight unless on a hill as i always leave in gear too, but with 215k, it's probably had quite a few pulls! Anyway, I need to use the car and managed to find a solution that appears to work, so thought I would share - doubtless someone will have the same issue soon. I found a small piece of sheet metal that was about the same thickness as the offending item. Firstly, I drilled out the 4 spot welds on the forward part of the plate - I decided that since the rear mounting bolt was unaffected and takes less of the upwards pull I'd leave it. Next I used mole grips to bend the plate backwards before cutting it off with an angle grinder. I didn't have to cut right through, as I was able to bend it clean off before I got right through. Filed off any rough edges and corners. Then I cut my piece of metal to size and trial fitted. I temporarily placed the handbrake on and marked when I needed to drill for the mounting bolt. The next task was probably not very technical but worked. I drilled through where the spot welds were. I then cut a cardboard template of my repair piece and put it in place. I used a small screwdriver and some careful 'peeling back' to mark the holes by pushing through with the screw driver where the holes were. I then placed the cardboard over my actual repair piece and marked, then drilled. Note - drill size to use is dependant on what size of rivet you intend using. I used the largest that I had in my Halfords rivet set. Having drilled all the holes in the metal, I then placed the mounting bolt and nut on - LEST I forget and rivet it without it in place! Hopefully all the holes wil align, place your rivets in then pop then all with the rivet tool. The handbrake assembly does foul the RHS rivets slightly - I ground back the handbrake mount very slightly until it sat flush. [*} Refit and reassemble. I would add that I would probably have put a small sliver of weld at the front to ensure strength, but as I don't weld and no-one was about, this had to do. I didn't have the right paints handy and will go back and paint in due course. Hope this helps if you have the problem and let you prepare your solution and have the car off the road for the smallest time possible. Jamie Quote Share this post Link to post Share on other sites
diarmaid16 1 Posted January 18, 2015 Nice job and write-up jamie. Had this problem before but a mate with a welder sorted it. Quote Share this post Link to post Share on other sites
