Running Head: HYDRAULIC HANDBRAKE FOR DRIFTERS 1

Using CAD, How Can a Hydraulic Handbrake Mount be Designed for Drifters?

Grant Anderson

Koruworks LLC

Table of Contents
HYDRAULIC HANDBRAKE FOR DRIFTERS 2

Rationale of Study 3

Research Concept 4

Chapter 1: The Problem and its Setting 5

Statement of the Problem 5

Foundational Context 5

The Problem and Method for Finding a Solution 6

Definition of Terms 8

Acronyms 9

Assumptions 9

Delimitations and Limitations 9

Importance of Study 10

Chapter 2: Review of Related Literature 10

Chapter 3: Data and Treatment of the Data 16

Evaluation and Needs of End Product or Client to Solve the Problem 16

Type of design and its underlying assumptions 16

Develop and Prototype Solution 17

Timeline, Management Plan, Feasibility 23

References 24

Rationale of Study
HYDRAULIC HANDBRAKE FOR DRIFTERS 3

` This study will analyze the effectiveness of a hydraulic handbrake mount designed using

Computer Aided Design (CAD) with constraints and requests given by the mentors at

Koruworks LLC. The owners believe that adding a new product to their current lineup would be

beneficial both for the business and for the market as it would increase supply and allow for

more variations of products. The research is universal because the test method is applicable to

any hydraulic handbrake mount on the market and can be performed in any environment.

Vasiljevic, Aleksic, Rajkovic, Đukic, Šarenac, and Bankovic (2018) write that “The use of

various modern software such as CAD and CAE [Computer Aided Engineering] technology,

enables us to perform various researches very effectively and efficiently... The benefit of these

systems is that they enable faster and cheaper research and development of the vehicle.” CAD

software is necessary for designing a hydraulic handbrake mount because it will allow for rapid

prototyping and creation of multiple revisions after testing.

This internship was chosen because of the desire to learn more about the automotive

industry from the perspective of a small shop, as well as learn more about the part design process

and gain hands-on skills for working with cars. This research will give good experience with

CAD, part design, and part testing.

HYDRAULIC HANDBRAKE FOR DRIFTERS 4

Research Concept

Chapter 1: The Problem and Its Setting

HYDRAULIC HANDBRAKE FOR DRIFTERS 5

Statement of the Problem

Question: Using CAD, how can a mount for a hydraulic handbrake be designed for drifters?

Study Purpose: The hydraulic handbrake is an integral part of a drift car, as it allows the

driver to break traction on the wheels with greater ease than oversteering. Every handbrake has a

mount that attaches the lever and hydraulic system. The supervisors at Koruworks LLC, an

automotive shop, want a hydraulic handbrake mount designed and produced for sale at the shop.

This research studied the design process and testing of such a mount.

Foundational Context for the Study

Foundational Subproblem 1: What is drifting and what are the basics of the sport and culture?

Answer: Drifting is an ever evolving sport involving the driving of a car while the tires

have broken traction with the ground, and requires various technologies to be performed properly

Solution: Information was gathered from 5 reputable websites and compiled to write a

literature review.

Foundational Subproblem 2: What are the opinions of professionals in the drifting field with

regards to the current hydraulic handbrake mounts available?

Answer: Current designs are exhausted and in an ever developing world of drift culture,

there is a larger demand for different styles of designs.

Solution: Interview three people who work at Koruworks and three customers. Use

information to write a literature review.

Foundational Subproblem 3: How can CAD be used to model and test a new design for a
HYDRAULIC HANDBRAKE FOR DRIFTERS 6

hydraulic handbrake mount?

Answer: CAD will be an effective design tool for the a hydraulic handbrake mount that will later

be machined. It also serves as the superior tool for visualizing designs.

Solution: Gather five peer reviewed sources about the effectiveness of CAD as a design tool, and

use information to create a literature review.

The Problem and Method for Finding a Solution

Applied Subproblem: There is a need for more hydraulic handbrake mounts in the market, and

the team at Koruworks LLC wants to become a producer and supplier of their own.

Objectives: The mount must be unique, stylish, and functional, as well as hold up in an

application setting.

Prototyping: The hydraulic handbrake mount will be designed in CAD, drawing ideas from 2

other products on the market.

Checklist: The design must meet two conditions: it must pass the mentor design evaluation and

hold up in a test setting

Qualitative Basis for Decision: The hydraulic handbrake mount must pass a supervisor check and

be able to withstand 25 pounds of force through a lever arm. If it passes these tests the hydraulic

handbrake mount will go into mass production.

Definition of Key Terms and Concepts

Computer Aided Design: “The use of computer systems to help in the creation, modification,

analysis, or optimization of a design.” (Vasiljevic et al. 2018)

HYDRAULIC HANDBRAKE FOR DRIFTERS 7

Computer Aided Engineering: “Computer-aided engineering (CAE) is a widespread use of

computer software to help in engineering analysis tasks.” (Vasiljevic et al. 2018)

Computer Aided Manufacturing: “The use of software and computer-controlled machinery to

automate a manufacturing process.” (Deans 2018)

Deformation: “The permanent change in shape of a metal object as a result of applied or internal

forces” (Anderson 2014)

Drifters: people who drift cars for sport reasons (Swig 2004)

Drifting: “Drifting involves keeping a car sideways (often in a four-wheel drift versus a simple

tail-out spin) through one or multiple corners, front engine/rear drive is the preferred racer

layout. Most any car of this type can be set up to drift, although performance modifications such

as a limited-slip differential and high-grip front tires make it easier.” (Swig 2004)

Hydraulic: “Hydraulics are machines designed to operate through fluid power. They transfer

force using a liquid, most commonly oil, and cover a wide range of applications from jobsite

excavators to commercial aircraft. Used across a spectrum of industries...” (Motion Industries

2018)

Machining: “Machining covers a wide variety of actions that take a raw material and turn it into

something else. It could be defined as a controlled process that takes raw material and transforms

it into a desired final shape and size.” (Advantage Machining 2018)

Milling Machine: “Tool which has rotating cutter and is used for machine parts into very

precise shapes and size” (CAMaster,2015)

Solidworks: “Parametric, feature-based solid modeling software” (Cohn, 2018)

Acronyms

CAD: Computer Aided Design

HYDRAULIC HANDBRAKE FOR DRIFTERS 8

CAE: Computer Aided Engineering

CAM: Computer Aided Manufacturing

CNC: Computer Numerical Control

Assumptions

● The researcher assumes all of the metal being machined and tested will be of similar

quality.

● The researcher assumes the mill will machine all of the parts virtually the same way

every time.

● The researcher assumes the lever arm will not deform.

● The researcher assumes the given weights are accurate.

● The researcher assumes the hydraulic system will compress evenly every time the

cylinder is compressed.

Delimitations and Limitations

1. Only one design of a handbrake mount will be tested due to economical restraints,

removing comparison with other brands and models - Limitation

2. Only a few test subjects will be able to be produced for the purpose of testing due to cost

constraints for materials - Limitation

3. Air resistance will be neglected in calculating the theoretical force applied to the

hydraulic brake mount because of the relatively slow speed and small surface area of the

moving parts - Delimitation

4. Solid frictional forces will be neglected in calculating the theoretical force applied to the

hydraulic brake mount because of the slow speeds - Delimitation

5. The deformity expressed by one test will have an effect on the next test because of the
HYDRAULIC HANDBRAKE FOR DRIFTERS 9

change in shape, skewing the results -Limitation

Importance of Research

This research is important because it demonstrates a testing method for hydraulic

handbrake mounts. As a researcher can perform this experiment with everyday items, it does not

require many resources to gather data. This would allow a small shop testing the effectiveness of

their design to gather data from both their design and other designs to compare the deformities

after being put under stress. The design that will be tested in this research will be sold on the

Koruworks LLC website if it is successful, and the researcher will revise the hydraulic

handbrake mount if it breaks under a small amount of force.

Chapter 2: Review of Related Literature

Introduction

The objective of this literature review is to analyze sources for three Foundational

Subproblems (FSP). The first FSP outlines what drifting is and various elements of the culture,

necessary equipment, and details of the sport. The literature reviewed for this FSP includes five

electronic website sources, including an article from Motor Trend magazine, an outline on
HYDRAULIC HANDBRAKE FOR DRIFTERS 10

drifting from the website for a racetrack that features drifting, and a comprehensive web page

sponsored by the Formula Drift (FD) organization that outlines the 2018 FD season. The second

FSP explores the needs and wants for a hydraulic handbrake design based on eight interview

questions from the Koruworks LLC shop. Interviewees include 3 people working at the shop and

three regular customers in the shop. The third and final FSP is an analysis of the effectiveness of

software systems such as computer-aided design (CAD) when designing and manufacturing

automotive parts. five peer-reviewed journals are analyzed in this FSP.

Literature Review

FSP 1

According to Swig (2004), drifting is presented for a person who is not quite a fan of the

sport. Swig (2004) says “As its name implies, the idea of drifting is to get a car sideways--and

keep it there as long as possible--simply because it puts a grin on one's face” (para. 1). U-Drift

(2011) further supports this notion that drifting is a fun sport by saying “Drifting is not always

the fastest way to drive around a corner or curve, but it is the most exciting way!”(The Basics of

Drifting). Both of these articles discussed how an everyday person can get into the drifting

culture, such as which consumer cars are conducive to drifting, some of the additional equipment

required to drive these cars efficiently, and suggests types of events a budding drifter could

participate in. U-Drift (2011) goes into much greater detail than Swig (2004) by giving specific

details as to what one needs to do to drift, such as extensive vehicle preparation and specific

techniques. U-Drift (2011) also specified the use of a handbrake, around which this research is

based. These ideas are further elaborated upon by Layton (2006), a How Stuff Works article that

goes into further depth on the topics presented in Swig (2004) and U-Drift (2011). The article

supported the expressed ideas, stating “In drifting, drivers force their car to slide sideways
HYDRAULIC HANDBRAKE FOR DRIFTERS 11

through a turn, and professional drifters can accomplish a true driving contradiction: They can

control what happens when their tires no longer grip the road” (p. 1). These articles are important

because they demonstrate the need for a handbrake in the act of drifting.

Swig (2004) provides an extremely general description of the culture and the cars used in

drifting in comparison to U-Drift (2011) and PASMAG (2018). PASMAG (2018) covered the

2018 Formula Drift competition season, which is the largest drift competition circuit in America.

It discusses in great detail how competitions are judged, what cars are used in competition, and

where events take place among other things. This article is meant to be an in-depth summary of

what takes place during the professional season. DNEWS (2012) is a helpful tool in digesting the

information presented in PASMAG (2018) by providing a general description of what Formula

Drift entails as well as explaining terms that may not be clear to the reader. DNEWS (2012)

describes the change in drift culture, saying “drifting has gone from underground competitions

between drivers fueled by adrenaline and skills honed by hours of sliding through back roads and

doing donuts in abandoned lots, to an organized motorsport with professional drivers, teams

backed by major sponsors, a national championship, and a growing legion of rabid fans” (para.

2). PASMAG (2018) and DNEWS (2012) are both relevant to the research at hand because they

outline the need for a hydraulic handbrake mount at the professional level.

FSP 2

Koruworks is the automotive shop that the research will take place, and the designed

hydraulic handbrake mount willbe sold there if it is a successful design. Six people have given

responses to questions regarding hydraulic handbrakes: those interviewed included three

employees in the shop and three frequent customers.

The employees at Koruworks gave professional opinions and observations on hydraulic

HYDRAULIC HANDBRAKE FOR DRIFTERS 12

handbrake mounts. Gregg Bucell stated he sees designs moving towards “making a universal

handbrake with specific brackets per car.” He also states that he sees that current designs are too

large and bulky and that customers desire a smaller design. Tyler Clayton supports this by saying

he predicts designs moving in a direction of “more compact designs to allow more mounting

locations and possible locations.” He says that while most customers are happy with the

available options, they want the installation process to be simpler. If Clayton was to design an

ideal handbrake, he says he would create a compact design that fits in between the steering wheel

and shifter while removing the need to damage the existing interior of the vehicle. Ryan Smith

further supports the idea of more customization of the handbrake, stating “customers typically

ask about different colors and mounting solutions.” He sees current designs moving towards

interchangeable parts, similar to Bucell and Clayton. All three of the employees have at least five

years of experience working on drift cars, and their expertise and insight is valuable because of

their background.

The three customers interviewed gave insight regarding their experience working with

drift cars and hydraulic handbrakes, as well as what they have seen in the field and their opinions

on designs. Shawn Smith, with fifteen years experience building and drifting cars as a hobby,

states current designs are “bulky and in the way.” Smith has worked with hydraulic handbrakes

before, installing two himself, but strongly dislikes current designs. He desires a design in which

the fluid reservoir is not mounted next to the driver, which is typical in current designs, and he

suggests a design in which only the lever arm is mounted next to the driver, and the fluid

reservoir is placed under the dashboard, out of sight. Chris Melde is a customer of the shop, but

he does not deal with drift cars in particular. From his observations, he has noticed that hydraulic

handbrake mounts tend to snap under normal forces, something not conducive to use. Melde
HYDRAULIC HANDBRAKE FOR DRIFTERS 13

suggests a “specific chassis bolt in design” with “Bluetooth lights.” Alex Grant, with 9 years of

drifting experience, states current handbrake designs have a excessive “amount of interior

modifications involved” and that the installation involves “often losing the parking brake.” He

sees current handbrakes moving toward a “less intrusive or OEM [original equipment

manufacturer] style.” Grant says that current handbrake designs slip because of smooth metal

and that a better shaped or grip covered handbrake would allow a driver to hold onto the handle

with greater ease. As consumers, the opinions above are valid because these are the customers

who could potentially purchase a hydraulic handbrake.

FSP 3

The five sources presented here outline uses of computer systems for designing and

manufacturing automotive parts. In Vasiljevic et al. (2018) the use of computer-aided design

(CAD) and computer-aided engineering (CAE) is discussed with regards to designing

automobile systems. The authors write “The use of technologies considerably reduces the cost of

testing and the research.” (Vasiljevic et al., 2018). Later, they outlined the situations in which

CAD and CAE cannot be used, such as during “analysis of the fatigue of the hot exhaust system”

(Vasiljevic et al., 2018). The aticle also stated, “With the use of these technologies we have an

overview in the design phase, because creating 3D parts in the space provides an ideal insight

into geometry” (Vasiljevic et al., 2018). This is important to the research at hand because it will

allow the researcher to create and develop a design for a hydraulic handbrake mount in a 3D

space. In(2016), Canuto da Silva and Kaminski outlined the product development process (PDP).

This paper highlights the “Virtual Prototype” and the “Physical Prototype” as important elements

of the PDP (Canuto da Silva and Kaminski, 2016, p. 1514,1517). These elements included

recommended techniques for 3D modeling a design as well as methods for rapid prototyping.
HYDRAULIC HANDBRAKE FOR DRIFTERS 14

This article supports the claims of Vasiljevic et al. (2018) because both defend the idea of 3D

modeling as a beneficial tool in the design process. Pandilov and Naumov’s Benefits of

application of CAD/CAM systems in metal processing companies (2017) further reinforced the

idea that computer-aided means of design are the superior method for creating designs, listing

various benefits such as “Decreasing or completely elimination of the prototyping needs,”

“Elimination of the irregularities that can be issued by manual making of the drawings,” and

“Fast and simple way for model corrections” (Pandilov and Naumov, 2017, p. 46). This piece

also highlights various popular CAD systems, such as Solidworks and Autodesk Inventor

(Pandilov and Naumov, 2017, p. 46). CAD/CAM/CAI (computer aided inspection) application

for high-precision machining of internal combustion engine pistons (2014) is a much more

specialized journal article in which authors Postnov, Khadiullin, Starovoitov, and Kilmetov

discussed the applications of computer systems in designing and manufacturing pistons in

internal combustion engines. The authors share similar ideas with the above articles in that they

agree that CAD is the superior design tool for parts, stating “CAD-system let us to adjust the

initial 3-D model in accordance with the technological requirements.CAD-system makes it

possible to design a fixture device for an workpiece” (Postnov et al., 2014, p.68).

Future trends in CAD – from the perspective of automotive industry (2017), by Hirz,

Rossbacher, and Gulanova, takes a different perspective on analyzing CAD by discussing both

the change in its use over the years and its potential future in engineering design.Hirz et al (2017)

states “During the past decade, the significance of these mechatronics technologies has been

raised from comfort-related features to integrated modules with a strong impact on drivetrain,

vehicle safety and automated driving functionalities” (p. 2). This is applicable to the research to

be conducted in this study because it shows the relevance of CAD in the present day. The article
HYDRAULIC HANDBRAKE FOR DRIFTERS 15

also says that CAD systems are moving to “simultaneous reduction of CAD program

complexity,” which is important to consider when deciding which software program to use in

order to successfully design a hydraulic handbrake mount.

Conclusion and Summary of Problem Solution

These sources form the basis for an understanding of the directed consumer for this

hydraulic handbrake mount, how one should go about designing features, and what technology

will be used to create the design. These are all important because this product needs to be created

in such a way that it is desirable by customers, and it must be designed correctly in order to do

so. By collating multiple sources, the researcher can design a successful hydraulic handbrake

mount to be sold by Koruworks LLC.

Chapter 3: Methodology

Evaluation and Needs of End Product or Client to Solve the Problem

The purpose of this study is to design and test a hydraulic handbrake mount to be sold at

Koruworks LLC. The designed handbrake mount must satisfy both the demands of the customers

as well as the supervisors at Koruworks LLC. The mount must meet the expectations of physical

appearance of Koruworks LLC. The team desires a mount that is unique, stylish, and functional.

The uniqueness and stylishness will be an opinion of the supervisors, and the functionality will

be determined by its ability to do its job through the testing methodology. The customers want a

mount that is different from the rest of the market with potential customization options not

offered by other companies. The supervisors at Koruworks LLC will review the design before

production in order to assure it meets their expectations, as well as after testing to make sure the

mount will work in an application setting. Koruworks LLC will sell this hydraulic handbrake in
HYDRAULIC HANDBRAKE FOR DRIFTERS 16

conjunction with other parts to make a complete hydraulic handbrake kit.

Type of design and its underlying assumptions

The researcher will design a hydraulic handbrake mount for use in a drift car. The mount

acts as a pivot for a lever arm as well as a point to attach a master cylinder and reservoir. It is

assumed that all mounts produced will be made in the same fashion from similar materials,

giving a consistent test sample. When testing, the mount will be put into use on a 2x4 board and

assembled with a master cylinder, reservoir, and lever arm as it would be in a vehicle. It will be

assumed that the master cylinder will compress the brake fluid the same with every movement of

the lever arm, and the lever arm is assumed to not bend while a force is applied to it. The mount

will be tested by hanging weights from the lever arm in the uncompressed position and then

releasing the weights, so the weights are assumed to be of the given weight.

Develop and Prototype Solution

The design will take influences from various other hydraulic handbrakes on the market,

most notable the Chase Bays and Wilwood designs. These designs have been selected by the

supervisors at Koruworks LLC because they like the shapes and structure, most notably the

isolated pivot point on the Chase Bays mount. and the cylinder supports on the Wilwood mount.

The hydraulic handbrake mount will be designed in Solidworks, a popular CAD software.

This software allows the user to create designs with an exact degree of positions, and supports

file exports in many file types, which is useful for sending designs to manufacturers. The

manufacturer will take the 3D file and create the machine code for the computer numerical

control (CNC) mill to produce the design.

HYDRAULIC HANDBRAKE FOR DRIFTERS 17

Test Solution

After preliminary design, the design for the hydraulic handbrake mount will be reviewed

by the supervisors at Koruworks LLC. If the design passes a check by the supervisors (meaning

it is unique, stylish, and functional), the shop will produce the part and test it physically. A check

includes Kerry Brown, co-owner of Koruworks LLC, looking at the design drawing and making

sure important dimensions and stylistic choices are up to his standards and abide by what he

wants. The methodology for testing will be as follows:

The researcher will assemble the hydraulic handbrake mount with an ISR lever arm and

a Wilwood master cylinder, and attached to the widest side of a 2x4x8 wood board. Placing the

board upright will position such that the lever arm can be pulled down. The researcher will tie a

rope to the top most finger hole of the lever arm, and to the other end of the rope the weight

being tested at that point in time. A set weight, ranging from 10 lbs to 25 lbs and going in

increments of 2.5 lbs, is attached to the rope, and held such that the rope is barely taught. The

researcher will then release the weight, and the falling weight will apply a force to the hydraulic

handbrake assembly. The weight will hold the hydraulic handbrake in this compressed position

for 5 second from the time of the drop. Thereafter the researcher will remove the weight, and

will disassemble the hydraulic handbrake setup and compare it to the control, a non-tested

handbrake mount. Deformity will be measured at 3 places on the handbrake mount: The top most

part of the mount, the handbrake arm pivot holes, and the end of the bottom plate. The researcher

will record these potential deformities, and visually inspect the mount and note other

irregularities. The researcher will put the same, potentially deformed assembly back together and
HYDRAULIC HANDBRAKE FOR DRIFTERS 18

repeat the experiment using the next weight.

In order to assess the effectiveness of the Koruworks hydraulic handbrake mount, the

researcher will carry out the same procedure but using a Wilwood hydraulic handbrake mount.

The Wilwood hydraulic handbrake mount is sold on most websites where hydraulic handbrakes

are sold, so its effectiveness is assumed to be one of the best.

Materials List for Testing

● 1 ISR hydraulic handbrake arm

● 1 Wilwood master cylinder and securing bolts

● 2 feet of

● 4 five pound Fitness Gear weights

● 2 two and a half pound Fitness gear weights

● 1 2x4x8 board

● 3 Koruworks hydraulic handbrake mounts

● 2 Wilwood hydraulic handbrake mounts

● 2 ⅜ inch wood screws

Analysis Strategies

The data collected will be intervallic because it is measuring the deformity in comparison

to the stock, unadulterated part. The statistics will be descriptive because the data collected

shows a simple comparison between the tested part and a control part. The amount of deformity

will be compared between the Koruworks prototype and the Wilwood handbrake mount, and

conclusions will be drawn based on these

HYDRAULIC HANDBRAKE FOR DRIFTERS 19

The data will be collected and placed into tables as shown below.

Note: more weight may be used than seen in the tables depending on discretion of supervisors

The data for the two tested Koruworks mounts will be compared to the untouched

Koruworks mount, and the data for the one tested Wilwood mount will be compared to the

untouched Wilwood mount. If the deformity is similar in both the Wilwood mount and the

Koruworks mount, it can be assumed that the Koruworks design is similar in

quality to the gold standard. If it is not performing at a similar level, the next

phase is to bring the results to the supervisors at Koruworks LLC. They will

make the decision whether to revise the design or choose to further produce

the Koruworks design because while they want to have quality similar to the

Wilwood design, it only matters that it works at a high enough level to be

used in a drift car.

A graph for data collection is shown below.

Methods of ensuring validity, reliability and consistency

All assemblies will be put together under the supervision of Gregg Bucell,

who with over 7 years experience of working with drift cars will be able to

assure that every mount is assembled correctly. Every handbrake mount will

be assembled in the same way, so there should be consistency between test

iterations. This test method emulates a situation in which the hydraulic

handbrake is in use in a drift car. If another party was to conduct research in

a similar fashion of testing a hydraulic handbrake mount, they could easily

complete research using this methodology.

HYDRAULIC HANDBRAKE FOR DRIFTERS 20

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HYDRAULIC HANDBRAKE FOR DRIFTERS 22

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