Brake Cooling Hose Manifolds-II

[moneymanager]

Inspired by George M, whose "Brake cooling hose manifold-Project Complete" here is required reading for weekend racers looking for brake cooling with an early car, I wanted to see if I could substitute aluminum for the plastic he used. Yes it weighs a bit more, and is harder to work with, but I thought it might overall just be easier to live with. WHile the jury's still out, I like so far what I've seen (IF this topic is of interest to you, read his thread then come back to this.)

Here are front and back shots of my aluminum tubing after cutting.





And here's the completed installation.





And this is the shot that shows you how you get the aluminum over the A arm.



Can you really spread the aluminum slit enough to get it over the 5/8" diameter A arm? Yes. Works like a charm. Try to get it right the first time, as you don't want to do it over and over, but simple hand pressure with no tools or wedges is all that is needed. If you screw up, you can do it again.
What kind of aluminum? Mine came from onlinemetals.com, was 2.5" in diameter with a wall thickness of .065, type 6061. I cut three pieces 8" long, figuring I'd have one for a spare. On my car, the slots at each end are 2 5/8" deep, leaving a 2 3/4" "unslotted" section in the center. I think a thinner wall tubing, which is available though maybe not at onlinemetals, would work just as well and be easier to slide over the A arm. A two foot piece like mine costs $18.22 plus shipping. (THis note added months later: cutting the tubes to 9--9.5" instead of 8" would let the hoses slide on a bit further...which would help keep them in place. If you added 1" to the overall length, to make the piece 9" long, you would of course make each of the slots 1/2" longer.)
Make sure when you cut the slots that both of them are in the upper 1/3 of the tubing...you want more of the tubing below the A arm than above for clearance.
WHen you are sure your slots (5/8" wide on my car) will fit over the A arm, slide it on in the correct orientation. Then put a hose clamp around it and pull the tubing tight. Now the hoses will slide easily over the ends and you can secure them with more hose clamps.
A similar commercially available kit shows the equivalent of my aluminum tubing clamped to the suspension to hold it in a fixed position. After over a years experience with my setup, I see no need. The tubing rides in the position shown without problems.
I used about 20" of flexible hose between my manifold and the brake backing plate, and about 18" to go forward from the manifold to the bumper. Measure, your car may be different.

[Kroggers]

Nice work.

[Bill Verburg]

Originally posted by Kroggers
Nice work.

Agreed!

[GeorgeM]

Nice work. Sorry I didn't see your comment from my original post.

The top of the tube is not much higher than the torsion bar part of the A-arm, so it would take an awful lot of suspension compression to crush the hose. I suppose the flexibilty of the plastic helps.

I'm in Baghdad, so I can't get under the car and confirm, just going from pics and memory. It has been a few years since that project.

[moneymanager]

You're forgiven. Keep up the fine work George. Decided that even though it didn't look like the piece would work without being crushed it had to or everyone wouldn't be doing it that way! And of course, all of you were right! So far, there are no signs of conflict with the aluminum. I wish you a speedy and safe return. Jim Taylor

[GeorgeM]

Thanks Jim.

Glad yours worked out.

Have we put Smart Racing out of business yet?

They do have some very well engineered, top-notch stuff. This particular product just seems a bit too pricey for what you get.

[moneymanager]

Agreed. I take great delight in making something on my own without spending much money. BTW, I ignored the attachment to the torsion bar case which you and SR both did. I wasn't intending to, but I just thought "I'll put these on and drive them around and see if they survive" before wasting any more time on them. So far, their absence hasn't made any difference. But for appearance sake, I'll add tie wraps the next time the wheels are off.
Car is going to Willow Springs this weekend for it's first visit to the track. The car is a 74 coupe, replacing a wonderful 73 Targa which has proven less suitable as I get more and more interested in race weekends.

[len911]

Check out this old thread... Some more custom metal work. Lou
Cool brake ducting, with pics.

[moneymanager]

Very nice. However I do believe my approach to fitting the tubing around the A arm gives a nicer result. It may also be a bit easier to cut, though that is arguable!

[ninesixfour]

What keeps the hoses from getting crushed due to suspension travel? Even with the manifolds the hose still has to go over the control arm before turning towards the rotor.

[moneymanager]

The second picture from the bottom in the above set shows where it lies. There's actually plenty of clearance. Note the comment above about putting the slots in the upper 1/3 of the tube...part of the answer to your question.

[ninesixfour]

Originally Posted by moneymanager

The second picture from the bottom in the above set shows where it lies. There's actually plenty of clearance. Note the comment above about putting the slots in the upper 1/3 of the tube...part of the answer to your question.

I'm not worried about the manifold itself but the tubing has to go up and over the control arm and at it's highest point is very close to the tub.

[moneymanager]

Not close enough to matter. It simply doesn't touch. I don't know anyone who has ever had a problem, though I'm sure they are out there.

[ninesixfour]

Originally Posted by moneymanager

Not close enough to matter. It simply doesn't touch. I don't know anyone who has ever had a problem, though I'm sure they are out there.

Ok I will take your word for it and give it a shot. My $11 manifolds are made and I'll get them installed soon...

[ninesixfour]

Well here they are. I may be able to put a zip tie on the tubing where it's touching the tub and pull it away just enough to clear.