Tutorial DIY 3D printed Sim Racing Hydraulic pedals SRT

I decided to test the CNC pedal using wood first. Good thing I did because it somehow didn't come out right. Possibly user error. I'll try again tomorrow.
Most of the parts I ordered arrived today except for the banjo adaptor and gaskets. I'm getting excited!

wow impressive @ibohan00 !

I finally got the banjo adapter. Unfortunately the MC that comes with the 2 cylinder caliper uses a 10mm x 1.25 thread and the banjo adapter uses 10mm x 1..
I'm thinking the easiest thing would be to order another adapter and wait another 2 weeks for shipping unless someone has a better idea?

The banjo adapter needs to be mounted on the slave cylinder.

I just checked the slave cylinder (brake caliper) and it looks like that also uses an M10x1.25 thread.
What's the reason for not having the banjo adapter on the MC side?

The master cylinder and pressure sensor are both using imperial threads, consequently we can find easily adapters.
Find an imperial to metric adapter is near of impossible...

On top of that, I didn't want to have the brake calipper moving everywhere and pulling on the sensor cable.

The company that sells the adapter also sells imperial to metric sizes
https://ebay.us/ZWL9YM - M10x1.25 to 1/8 NPT
https://ebay.us/JIYkci - M10x1.0 to 1/8NPT

My problem was that I ordered the M10x1.0 assuming that was the correct thread pitch for the 10mm banjo. It's actually M10x1.25.

I agree the sensor would be best on the master cylinder

Well, it's not perfect either. The sensor is quite high, and comes quite near of the lever. It's not touching, but...

Can you put a picture of how the banjo is threaded? it did not screw me at all but with Teflon it does not lose liquid.

The thread pitch is the spacing between each thread. If your parts fit together then they're the correct size. A banjo with a 1mm thread pitch won't physically fit into a 1.25mm pitch hole.
Here's a picture of what my M10 x 1mm banjo looks like.

I see. My master cylinder has the banjo in the back, so I don't think I'll have the same issue. I see a few people make their pedals using plates and I might be able to design something with clearance for the wires. How close is the pedal getting to the wires?

I have no problem with the pedal, it does not touch the sensor cables. What difference is there between putting the pressure sensor on the brake caliper versus putting it on the master cylinder?

@7HUND3R no major difference. I prefered to mount it on the MC because the brake calipper is not necesseraly fixed, and I didn't want the brake calipper pulling on the sensor cable.

@7HUND3R I've been thinking a lot. Finally, I think that I will mount the pressure sensor on the brake calipper or slave cylinder. It will be easier to bleed the pedals, and I need this setup to build the hydraulic handbrake.

Yes, I am thinking of changing the pressure sensor and placing it in the brake caliper and in the slave cylinder. But I guess you have to place a piece similar to this

M12 12x 1,5

https://www.ebay.es/itm/304-Stainle...1-8in-NPT-Male-to-M12x1-5-Female/223961360374

M10 10x1

https://www.ebay.es/itm/Metrico-Ada...345536?hash=item2646215000:g:xsAAAOSw8w1X9gxa

It is a kind of T in which it is connected to either the brake caliper or the slaver cylinder and here the pressure sensor and bleed plug would also be connected.

I already have this part, but it is impossible to find the good one (M10x1.25). On top of that, the quality is worse than the part I advice...
I am waiting for this one to land :
M10 X 1.25 Acier Inoxydable 20 Mm Banjo Bolt avec 1/8" NPT contacteur de frein port

But if you put that piece in the scalve cylinder, where do you connect the bleed plug?

https://es.aliexpress.com/item/4000418308059.html?spm=a2g0s.9042311.0.0.274263c08Yi8sA

I have that model of slave cylinder and the bleed plug has it in the same connector where the hose connects.

The brake caliper has the hose connector in one location and the bleed plug in another location.

Hello @Lebois, let me tell you.

I think something is wrong with the design of the brake pedal lever. When I want to bleed (fill the brake fluid circuit) I have to disassemble the lever and press the master cylinder with my hand since the pedal lever does not fill the circuit well. If you press the master cylinder by hand, the circuit is well filled. 2 things can fail, either the part that holds the master cylinder or the pedal lever.

Well...it feels strange to me. In my opinion, the problem now with the bleeding procedure is that air bubbles can be stuck in the banjo bolt with pressure sensor... It will be solved if the pressure sensor is plugged in the brake calipper.

Maybe the problem could come from the fact that the master cylinder isn't flat once in the support, but i don't think so.

I think a quick request might be to put washers under the master cylinder bracket or under the KP001 to raise either the pedal or the master cylinder. It is that they do not coordinate well in a straight line between the pedal lever and the master cylinder bolt. When the brake pedal travel reaches 100%, the master cylinder bolt bends down a little.

I have created 2 brackets for the brake caliper of the 1 piston and 4 piston model.

I have to buy them.

I already added a support for the 4 pistons, but thanks

I don't think that it's a problem that it's not perfectly aligned, it's designed in order to work good this way.