New Brake switch for my front TLS Drum brake

Ned · Jan 18, 2017

Thought I'd show some pics of my new switch for my TLS front Drum.

When I got my bike it had a non brake switch cable, so it never had a switch. I decided to purchase the proper switched cable for my brake which I have ran for over a year now.

To be honest, the feel and performance is crap.

So I thought I'd see if I could use a different switch and go back to a solid cable. I got onto Venhills website and ordered a new H/D non switched brake cable and also noticed they sell micro switches so I got one of them too.

A friend with a workshop drilled and tapped a hole for the switch and then made up a brass tube and a rod to run from the switch through the casting onto the perch lever.

The void was filled with JB weld to keep everything in place. So far so good, have yet to give it a road test but is working great as it stands.

Here's my fix.

New Brake switch for my front TLS Drum brake

Fast Eddie · Jan 18, 2017

Very neat !

texasSlick · Jan 18, 2017

That is slick!

Slick

robs ss · Jan 18, 2017

I like that idea, may reduce the sponginess of my current cable (includes plastic switch)
I'll check for fitment in early-mid 60s type brake lever castings - hopefully good news
Added bonus that wires to existing switch may have same length , or longer, than required for this mod.
This is one for the "up there for thinking, down there for dancing" file
Cheers
Rob

Danno · Jan 18, 2017

Very clever. Almost looks factory.

concours · Jan 18, 2017

[video]https://youtu.be/3pcqVQe-4z0[/video]

Good job!

DogT · Jan 18, 2017

That's real nice, but how do I put that switch on my early lever set? I'll have to work on that one. I really would like to get rid of that sponge I have for a front brake cable now that my TLS actually works.

concours · Jan 19, 2017

DogT said:
That's real nice, but how do I put that switch on my early lever set? I'll have to work on that one. I really would like to get rid of that sponge I have for a front brake cable now that my TLS actually works.

http://www.jpcycles.com/product/zz34329 ... aQodB4MDXA

Drill & tap M3, drill hole for the pin. Fab a tab under the lever to actuate

rivera · Jan 19, 2017

DogT said:
That's real nice, but how do I put that switch on my early lever set? I'll have to work on that one. I really would like to get rid of that sponge I have for a front brake cable now that my TLS actually works.

Yeah, it caused this in my case. Got stuck between the lampshell and all the cables and struts , front brake blocked on gravel road:

concours · Jan 24, 2017

A rather ingenius, rustic type switch, AR style. Godspeed Wes.

robs ss · Jan 25, 2017

I think I have a solution for older (early & pre-commando) brake levers. Ned's solution won't work here as the minimum switch thread size is M8 and the thickness of the handlebar casting is 9mm in the area where the switch needs to be mounted.
My idea, no clothespegs involved, is based on a shaped alloy bracket below the handlebar casting and another actuator plate screwed to the underside of the lever.
It is based on the M8 Magura switch (there are a number of sizes)
I'll post photos here of the finished item when ready
Thanks for the original idea Ned
Cheers
Rob

Anglophile · Jan 25, 2017

Here's my version of the solution:

https://flic.kr/p/RiTnhf

https://flic.kr/p/QfPvCj

robs ss · Mar 3, 2017

Okay - here's my first pass at a solution (based on Ned's idea) for pre-Commando bikes.
As previously alluded to, it's based on an underslung alloy bracket for the Magura M8 (normally ON switch) and a striker plate fixed to the underside of the brake lever.
Both the bracket and the striker plate are fixed by M3 SS screws tapped into the original brake bracket/lever, other than the striker plate also using the pivot screw. This also gives the advantage of only needing to need to remove two M3 screws, and pivot the striker plate away, to remove/refit a brake cable nipple.
The striker plate is only 1.2mm - but more than stiff enough to acute the switch.
Any suggestions for improvement?
Cheers
Rob

rivera · Mar 3, 2017

That´s great!
I have these early brake levers on my bike.
Where do I get the bracket for the switch?
Googling Magura M8 turned up nothing.
Cheers
Uli

robs ss · Mar 3, 2017

The Magura switches, as Ned advised, are available on the Venhills site, see link:
https://www.venhill.co.uk/Controls,_Lev ... _grey.html

The alloy bracket and striker plate I made myself. I'll attach more photos of the bracket/plate if it will help you make your own
Cheers
Rob

rivera · Mar 3, 2017

Thanks Rob,
is see the switch has an M8 thread.
Is there a thread in the bracket also?
Cheers
Uli

robs ss · Mar 3, 2017

Uli
Yes, the larger hole is tapped M8 X 1.0mm. The other 2 holes are 3mm, including the badly done elongated one!
It was cut from a single piece of aluminium using hacksaw, files, Dremel and wet & dry (abrasive paper)
The switch holder is purposely out-of-square (you can see the slight angle in the second photo) so that the switch matches the angle of the brake cable (so the wires can be strapped to the cable)
The small "foot" projection, seen in the first two photos, is to match the brake bracket and prevent any tendency for this new bracket to "roll" (as the brake bracket is curved)
The final dimensions are, 36mm long, 16mm wide and 19mm high
Hope this helps you
Cheers
Rob

rivera · Mar 4, 2017

Thanks Rob!
Will try it !

vercu · Mar 5, 2017

Did something similar with my Norton P11A.
I don`t want to modify anything. A bolt on solution is preferred.
First thought was to create something like a Laverda 750 SF had.

But canceled that approach because i didn’t`t want to disturb the special made HD Venhil front brake cable.
In an internet forum a watertight Marquardt micro switch was recommended as a brake switch.
Found a 1058.0553 cheap on eBay and made some small brackets from 1mm aluminium sheet metal.

Other than in Rob`s solution these brackets are only held by friction of the nut and the screw. Since the actuating forces are low for this micro switch i hope that this works. Have to test this in the upcoming riding season.

Peter

DogT · Mar 5, 2017

I like it. I too don't want to drill and tap holes in my original lever set. Don't see why it wouldn't work. Couldn't find the Marquardt switch but looks like the Omron D2HW-C202M from Mouser will be about the same. $7.