Bracket fabrication Qs:

[MFortie]

I need to fab a bracket for my Jeep Gladiator to mount a brake system breakaway air cylinder. I can't for the life of me find any place to mount this thing and came up with an idea (using cardboard) to make a bracket.

I know diddly about working with sheet metal, so have some questions. My thinking is to buy a brake and bend a 5" - 6" wide piece of sheet metal into the shape below (bracket is in black).

I don't know what material would be best to use: sheet steel, aluminum, SS? And what gauge (or thickness)? And in what order would I do the bends (starting from the bottom going up and to the right)?

The cylinder is just under 12" tall with a solenoid and fittings on top and about 2" in diameter. My guess is it weighs 1 - 1-1/2 lbs.

The gauge of metal will determine how much I'll spend on the brake. But one of the Woodward Fab 3-in-1 finger brake/shears looks interesting.

Thoughts?

Thanks...

 

[Gunfixr]

There's still a lot of open variables even with the size diagram.
What stresses are on the cylinder, as far as pushing in any direction?
How much does it weigh?
How will the cylinder be attached to the bracket?
Where on the vehicle does it mount?

 

[MFortie]

The cylinder just ‘hangs’ on the bracket and is mounted with a pair of cushion clamps. The only stress would be the weight of the cylinder which is roughly a pound or two.

The bracket ‘loops’ over the fender and the hood closes over it - the view would be from the front of the Jeep - and the bracket mounts via the RH flange with two M10 bolts on a corresponding flat on the fender. The fender shape is basically the same profile as the bracket.

The location is next to the brake master cylinder.

 

[WILD-BILL]

The gauge of metal will determine how much I'll spend on the brake. But one of the Woodward Fab 3-in-1 finger brake/shears looks interesting.

Thoughts?

Those 3 in 1 brakes are rated for 20 mild steel and IMHO I think that's a bit optimistic.

I would want something a little more substantial if I were building it. You need to consider vibrations/harmonics from the engine bay and the vehicle while driving as well as any flex from weight transfer of the unit during a jarring impact like a pothole.

I would use 16 ga steel personally.

what does this breakaway air cylinder do? What's the purpose?

 

[MFortie]

Those 3 in 1 brakes are rated for 20 mild steel and IMHO I think that's a bit optimistic.

I would want something a little more substantial if I were building it. You need to consider vibrations/harmonics from the engine bay and the vehicle while driving as well as any flex from weight transfer of the unit during a jarring impact like a pothole.

I would use 16 ga steel personally.

what does this breakaway air cylinder do? What's the purpose?

After a bunch of web surfing, I agree. I decided on 1/8” mild steel and ordered a SWAG finger press brake for my 12 ton HF press.

The air cylinder is part of the braking system for towing the Jeep behind our motorhome. There is a lanyard connected to the coach which dumps the air into another cylinder attached to the Jeep’s brake pedal in the event it becomes disconnected. The brake pedal cylinder controls the braking effort when towing the Jeep via an airline connection to the MH air brake system.

 

[WILD-BILL]

Gotta link for that system? Sounds like a cool alternative to an electric setup.

My parents are considering towing their Jeep Commander behind their MH and this might be of interest to them.

 

[MFortie]

Gotta link for that system? Sounds like a cool alternative to an electric setup.

My parents are considering towing their Jeep Commander behind their MH and this might be of interest to them.

It's from Roadmaster: https://www.roadmasterinc.com/products/braking/brakemaster/brake_m.php

Does their coach have air brakes?

 

[slowtwitch73]

Could always just mig it up if you have a welder....

 

[WILD-BILL]

Yes it does.

Thanks

 

[MFortie]

So, I ended up fabbing up the bracket to mount the cylinder. Turned out pretty nice:

 

[mrjaw14]

Man that looks nice

 

[pb57]

Nice professional looking job.
Paul

 

[mikegt4]

Nice work!

 

[laser3kw]

shows you that if you can dream it, you can have it
nice work, looks great!

 

[Lefty's Garage]

That's one of those 'problem solved' solutions that brings a smile to your face every time ya see it. Well done.

 

[mkat1951]

Looks good!! Good call on the swag finger brake over the 3 in 1 as well.

 

[PugetDude]

Bracket looks great!

I had that same setup on my motorhome, ours was a Tiffin class A gas- no air brakes. No problem, they just installed a small compressor in one of the cargo bays. It worked great for the 5 years we owned the rig.