delco brakes get them working successfully and well

[dodge1979]

Mark, just use one copper washer with a good surface area that fits between the two flat outer mating surfaces..don't build up a shape to fit in the recess out of several.. The new accumulator will be fine it tells you the capacity and working pressures stamped in the casing.

 

On another note, I was hoping to hold off giving any information out yet, but since last year Ive been working on the system again to develop further improvements. I knew a while ago regarding the supply issue, but I was told it would be sorted by the end of last year. However, a combination of several things pushed me on to new avenues.

 

Basically, having done the work, testing, spent the time and at my own costs in getting this setup working and correct, It was a bit of a kick in the balls to have the system given to Paul Mattys by someone (for whatever benefit of theirs) and then have them take it and start passing it off as their own work at highly inflated prices. I think it was underhand and as they were incapable of having done the work themselves in the first place, they should perhaps of gotten in contact with TLF as a gesture of respect at least and discussed it further. Now, as someone has mentioned earlier, because of their commercial greed the switches have all been bought up and are not available to forum members, which was the whole point of me having gone to all the effort in the first place! Transparancy from the start enabled other people to follow and successfully fix their braking problems, now people who had hope have now been let down because, I believe, of Mattys ignorance. Ill add that at no point have I had any contact with them or affiliation in any way about this or indeed anything actually, so this situation was unfortunately out of my hands before I knew it had happened.

 

As you may be able to tell, that's annoyed me for a while now, but Ive kept quite so far for a reason.

 

Next, Ive always wanted a neater solution. Im not a fan of two switches, various adapters and connectors etc..whilst it works well, its not the solution I ultimately want. I want a neater, one switch solution which can be supplied to owners with a simple fitment guide, a ready made wiring loom if possible and not using adapters and fittings and being made a bulky instillation as a result of this. Basically I want an easy interchangeable with the original unit 'fit and forget' item.

 

Which brings me onto my latest development's. Ive again spent a lot of time and effort and at my own expense again, in conjunction with a UK company, creating a solution that meets my criteria. Without going into details yet, I have paid for a prototype unit to be made and Im awaiting its delivery at the moment so I can fit to my Esprit and start testing it. Im hoping that, if all goes well and it proves to function as I have deemed it should, it will solve the issues of;

 

initial supply of the unit

the length of time it takes to be delivered to the user

the long term extension of its usefull life

the bulky fitment

simplifying its instillation

excessive costs (ie mattys or ordering from half way round the world)

and a fingers up to mattys as Ill have outdated what they've copied (personal goal)

 

So  if people can bear with for the time being, Im hoping Ill be able to give positive reports over the very near future and Im hoping I can pull this off....

[markw996]

Thanks Darren, I look forward to a final solution to the switch problem and really hope you can pull it off after all the hard work and testing you have done to help us fellow S4 owners.

 

I don't want to hijack this thread so this will be my last post until I have something relevent to say, but for anyone reading this in the future I have another short follow-on video showing my test with the new accumulator connected up.

 

http://youtu.be/X1FPgZ_wVMs

 

As you can see my pressure switch is obviously still faulty, but the new accumulator has made a significant difference to the operation of the brakes:

 

Initial ABS pump run time from completely depressurised:
44 secs down to 23 secs !!

 

Accumulator precharge pressure:
500 PSI up to 1200 PSI

 

Pump runs:

Every press, up to every 3 presses of the pedal

 

I haven't got it fully back together yet so don't know if I will feel a noticeable difference at the pedal while driving, but I suspect that even if the initial bite is no better, the car will stop quicker and feel safer overall.

 

Thanks,

Mark.

 

 

[top-plumber]

Nice one Darren, as mentioned in PM keep the main details under your hat and re coup your time and money investment, I'll be your first customer. Keep up the good work and see you at TLF meet.

Wayne

[lotus4s]

Kudos Darren

 

Hope it works out as planned as it will be a huge benefit to the community...

[jonwat]

Well done that man, keeping the cars on the road is worth the effort - shafting Matty is pure bonus. 

[rizla603104]

I look forward to seeing how Darren gets on with his prototype - it is surely a labour of love!

 

I bought the system from Australia and Gerald at GST fitted it and a new accumulator to the car. All I can say is - WOW! What a transformation to the braking. And of course - no flashing light! I am so thrilled that the brakes match the car now. Completely agree about the difference the accumulator makes. Interesting that before the new accumulator - it took 70 pedal presses to discharge and now it takes 40. Is that the way to tell if your accumulator needs replacing?

[dodge1979]

Not really. The best way to tell us with a test pressure gauge fitted and observe the initial pressure as soon as the pump begins running from a depressurised system. That coupled along with how well it increases the pressure..ie does it appear to struggle a little initially..and the pedal feel itself. A little soft on the pedal could indicate a worn accumulator even if the switch was running the system up to correct pressures. And sometimes t h e number of pedal presses inbetween the pump running...all are symptoms.

It may be that the capacity or pressure rating of your old and new accumulator are different. Out of curiosity do you still have the old one to check against the new one?

[rizla603104]

Interesting. I think what you described was my brakes all over. The accumulator has certainly made a difference. 3 days on and no flashing light. I was shown the old accumulator earlier - but didn't make any note of differences.

[dodge1979]

Ok guys heres the update.

 

A NEW ONE SWITCH SYSTEM IS AVAILIBLE  

 

As mentioned a short while back, Ive been developing a replacement again which I wanted to be a one switch system as per the original unit. Having paid for the initial development unit to be made as per my requirements, Ive spent the past few weeks testing it with great success. The unit is made here in the UK using a military application unit and as such supply should be no issue. The company I have been working with on this project are remaining nameless (their choice) at least at the moment. They do not deal with the general public and only supply in certain industries, however, it was by happen chance that I contacted them and my initial enquiry was picked up by one of their technical engineers who happens to own several Lotus cars (elites etc) and as such took the project on as a 'curiosity' problem...it pays to have a common passion!

 

As such, without the boring details, the problem was addressed and the solution was found. Ive successfully covered nearly 400 miles using the new switch and its functionality is excellent. Ill list its attributes and benefits;

 

One unit - smaller installation space required, simplified wiring, neater solution

 

Control of low pressure warning system - included in the unit, working as per the original alongside the control of pump functions

 

Robust casing - shock proof, vibration proof, more than adequate water resistance on wiring connections, as mentioned this is a military grade unit

 

Improved internal construction - improvements over the previous type unit in terms of it accuracy, longevity of use, reliability and quality

 

Pressure spike dampening - whether or not anyone else has ever noticed, there is occasionally a slight spike in pressure when the pump runs, this can give a slightly fluctuating reading of pressure and as such affect the 'feel' of the pedal and its performance. chances are though you wouldn't notice, it is very slight, but the opportunity to remove this and make an even more consistent functioning unit is incorporated in the design of this one

 

Functioning indicator - The unit includes a coloured LED functioning, which enables you to quickly see if the unit is registering UNDER the minimum pressure, PUMP RUNNING to bring the pressure up to maximum and MAXIMUM PRESSURE reached, this is a simplified function but is a good visual indicator that the system is also working correctly.

 

So from just the above few points you can see this new switch has many advantages over the previous solution, and indeed possibly better than the original unit due to its basic functioning LED indicator.

 

In terms of actually fitting the unit it is a fairly simple affair, but obviously the previous guide to system maintenance and bleeding still applies. As a competent mechanic, if you can service your own engine there is no reason why you cant sort out your brakes!  Unfortunately, the only down side is that it does require a thread adapter to fit into the pump housing. The original M14 thread isn't supported these days in this type of manufacture so a short adapter will be used, but this doesn't affect its functioning or fitment.

 

Now, as mentioned I have tested this well and I am happy with its ability to control the low pressure warning light system, the pump functioning and I also believe that due to the included pressure dampener, I feel the pedal has a more consistent feel to it also. Infact this was one of the first things I noticed...however I am massively OCD and do notice these things more than most!

 

As mentioned on my previous post, I am hoping to put together a complete package which includes the switch and thread adapter, wiring and instructions on its fitment. I am currently attempting to source the correct wiring plug connector to enable its direct fitment straight into the existing wiring loom. I cant promise this will happen as it is slightly different from the standard AMP connectors, but I am still searching. This will enable an easier fitment with less wiring involved.

 

As for price, this still needs to be discussed with the company involved and then I can let you know cost, and how to purchase.Im afraid Ive had a lot of other things going on at the moment so this isn't too high in my priority list but I am still working on it.

 

Hope this news helps some folk out! 

[dodge1979]

[dodge1979]

Above is a picture of all three switches, the original unit top left, the previous replacement to control the pump functioning is central, and the new wonder switch bottom right. I still have a thread adapter attached to the original switch as I used this as my low pressure warning light controller, hence why its a bit bigger than normal.

 

The new switch will require an adapter to fit pump body,however as there is only one switch being fitted, the requirement for an array or t-piece adapters and pipework isn't there as it was with the previous two switch solution, which mean instillation space is less and its a much neater fitment. Also, the wiring on the new switch is a smaller cylindrical fitment, unlike the previous one which is a larger block.

[markw996]

Excellent news, put me down for one as soon as you are ready to start supplying them

[Bibs]

Great work mate

[Gasman GT3]

Nice one Darren, thank god for people with your level of perseverance.  As per our pm chat I thought I may have had a dicky switch which was causing my ABS light to come on, but decided on a stepped approach to sort the issue.  Due to the fact the low pre charge was showing as a fault code I ordered a new accumulator from the USA which arrived yesterday.  Due to the great exchange rate at the moment I suggest anyone who needs one orders it now.  Including shipping, tax and the unit just £101, much cheaper than here.  As Darren said earlier you just need a copper sump plug washer to seal it (£1.40 for three). 

 

I fitted the new accumulator today and bingo no ABS light, and the pump runs every 6th pedal press, rather than every one before.  So for now all sorted, but its comforting to know should the switch fail we now have a viable alternative.  Thanks again Darren.

[top-plumber]

Hey Gasmang, I had the same issue with my car and replaced the accumulator, pump runs at the normal rate again now 6 peddle pushes, however you will probably find that the system is running way under its normal operating pressure because the old switch is tired. This was the case with mine. As Darren suggests in the thread install a pressure gauge and see what you are actually achieving.

Great work Darren

Regards

Wayne

[OwenGT3]

Great news.

I'm assuming the switch will be preset pressures, if so can it be guaranteed that the setting will work for every Esprit?

I have the Lotus Marques replacement switch on my car, although the switches were preset, the settings didn't work for my car. Once I fitted a gauge I was able to adjust the pressures and the switches were fine then.

Edited May 17, 2014 by OwenGT3

[dodge1979]

With regards above comments, accumulators are available in the uk for the same price. £100 including delivery. No fluctuations on price for exchange rates and they can be with you next day..

The switch is pre programmed correctly and there is no function nor requirement for adjustment. As mentioned it is a much better unit than previous and doesnt rely on pressure diaphragms for its internals (this is why you were able to adjust the upper hysteresis as it was set wrong from oz). This ensures its life span will greatly outweigh anything else and its consistency and reliability is second to none.

All the esprits using this delco system run at the same pressure..s4 s4s sport300 uk usa europe etc. They all use the same units the same fitments. The only difference is the side the steering wheel (and thusly the brake booster unit) is located on.

[rizla603104]

Well done! Great job. Any idea on price for the switch?

[tjs98jetta]

Darren,

Thanks for all your excellent work on this topic, I've been following it closely.  I'm definitely interested in buying one of the replacement switches if they become available.

Cheers,

Trevor

[dodge1979]

They will be available. As I said ive just got lots going on at mo and need to organise prices etc for you guys. Im on it just bear with me!

[lotus4s]

Great work Darren! You have and continue to do a great service for the Esprit community, thank you

[alan]

Hi Guys,

 

I could do with a bit of advice on my S4s brakes.  I must start with the admission I have not used the car for 6 months..

 

Last week I ran it up the road for a MOT and it passed no problems.  Yesterday I decided to take it for a run locally and found the brake performance to be poor, but just assumed it was down to lack of use.  After a few stops from speed, I noticed the brake warning light (not the ABS, the combined parking / brake warning light) comes on during braking and then goes off just after the brakes are released.  The ABS seems to cut in normally & the ABS light does not come on.  Over 2 test drives I braked hard probably 20 times, the light also came on with fairly gentle braking (no ABS).

 

The manual says this light comes on when low pressure is detected during braking.

 

Fluid level looks OK, but the rear reservoir is a bit cloudy / milky (the workshop manual says this is normal due to sealants / lubricants used in the initial assembly, but as the car is 18 years old that does not seem likely as they should have been washed out years ago).

 

Any ideas what to check?  It was working fine when I last used the car.  Its always been services by Gerald at GST performance so sure fluids have been changed on schedule etc.

[Bibs]

Plug in Espritmon mate and you'll see the ABS error codes. That's the best bet initially.

[alan]

Plug in Espritmon mate and you'll see the ABS error codes. That's the best bet initially.

 

I have a really old (RS232 interface) but I thought that only did engine codes not ABS?

 

Looked in the online shop to see if you now sell a shiny new USB version but could not find one?

[Bibs]

Speak to Chris (internets) on here, he'll supply a cable and have a read of this...

 

http://www.thelotusforums.com/forums/topic/57219-espritmon-update/

 

You're thinking of Freescan, Espritmon is Freescan on steroids just after a trip to the gym