944/Thing ebrake hook up success

[Kubelmann]

After much research, trial and error and interaction, today I got the ebrake cables configured, modified and installed. Thanks to a pal who was kind with parts I was able to complete one more step toward driving Herr K. If anyone is thinking about using 944 rear arms on a VW please let me know so I can share what I have learned. The ebrake outer cable sheathes for a 944 are far superior to any VW part. The cables are heavier gauge. I did some special fabrication to make the cable very resistant to any off-road harsh conditions. This part of building the car has been one of those part that you put off to the end. Then you have this huge pile of little tasks. I am thrilled to have found a very strong solution to this issue. Thanks to many out there that have helped me with this issue. K-mann

[Bob Ingman]

Kubelmann I was just thinking that when someone changes to longer/wider arms a similar situation results. Will your method be of use to someone needing to extend stock e-brake cables after rear arms have been extended? Thanks. Bob Ingman

[Kubelmann]

Bob, You bring up a good point. The 944 has an ebrake cable system that is made up of one long cable that is around 1975mm that goes from rear brake to rear brake. Then a second cable that joint the big one in the middle to go to the ebrake handle on the outside of the driver's seat. The Stock VW Thing ebrake cable is 1775 mm. So that means you have about 200 mm or 8' extra cable to allow for extended arms. It just depends on how your ebrakes hook up in the rear if this would work. The front end of the cable on the 944 is the same as bug/Thing/etc. So you could perhaps modify the end that hooks to the brakes. At this point given enough parts cables could be made that would work. Also there is the fact that most after market larger rear arms are set up to hold stock bearing, stubs etc. So perhaps you could use 944 brake system on an aftermarket arm. Then you could do the exact modifcation that I just completed. The cable housing is way too long for this application. The good news is you can put the fitting on the lip of a vice and pull the end clear. Then take your hand grinder and cut the housing shorter. Make sure the end of the housing is smooth. Then reinstall the end. I sealed the end using the rubber sealing tape used on underwater connections such as well pumps. Then I covered that with haevy duty shrink tubing. It came out very clean and will never leak or come apart. You will need two complete sets of emergency brake cables so that you get two long sections. The good news is with two complete sets you will end up with 6 cable housing that are the exact same length. So you can do some trial and error work to make your housing just right. Remember when you shorten the length of the brake cable housing you in effect lengthen the cable. Some other advantaes of the 944 parts include a teflon liner inside the ebrake housing, a spring and retainer system at the ebrake end and a heavier cable. The housing is also very much heavier and better protected than any VW part. At this point I could fab a set of cables for someone here and ship them out given the parts. There are loads of these part out there as loads of 944 have been salavaged for some of the more valuable parts. Another advantage to the 944 rear brake system is that the ebrakes are separte from the caliper and rotor. The ebrakes are internal brake shoes with drums that are part of the hub. This is how modern cars are being done. So it gives you a 25 year advance in braking technology. K-mann