CAD D ESIGN P ROJECT D ARYN M EGAW D AVID G ORDON G ARETH E DWARDS D AVID B ELLINI M OUNTAIN B IKE D ISC B RAKING S YSTEMS M OUNTAIN B IKE D ISC B RAKING S YSTEMS

S TANDARD C ALIPER D ESIGN  POOR - MODERATE BRAKING PERFORMANCE  POOR IN WET CONDITIONS  USES STANDARD LEVERAGE RATIO

V EE B RAKE S YSTEM  MODERATE - GOOD BRAKING PERFORMANCE  APPLY PADS TO THE WHEEL RIM  POOR PERFORMANCE IN WET CONDITIONS  USES VEE BRAKE SPECIFIC LEVERS

D ISC B RAKE S YSTEMS  STRONG, EFFECTIVE BRAKING PERFORMANCE  GOOD PERFORMANCE IN WET CONDITIONS  CONSISTENT, SMOOTH APPLICATION OF BRAKING  SLIGHTLY HEAVIER THAN CALIPER OR VEE BRAKE SYSTEMS

T YPES O F D ISC BRAKES Mechanical Design  LESS EXPENSIVE THAN HYDRAULIC DISC BRAKE SYSTEMS  WORKS WITH STANDARD RIM BRAKE LEVERS  SIMPLE ADJUSTMENT AND MAINTENANCE  NOT AS SMOOTH OR POWERFUL AS HYDRAULIC DISC SYSTEMS Hydraulic Design  COSTLY  SELF ADJUSTING  PRECISE AND POWERFUL BRAKING  HIGHER MAINTENANCE REQUIRED  REQUIRES HYDRAULIC LEVERS

I MPROVEMENT G OALS I MPROVEMENT G OALS  I NTERCHANGABLE H YDRAULIC / M ECHANICAL U NIT  V ARIATIONS I N B RAKE R OTOR O PTIONS  I MPROVED B RAKING S URFACES  E ASE O F A DJUSTABILITY  B ETTER M ODULATION  L OW U NIT C OST

O VERALL D ESIGN A SPECTS  R ECOGNIZE I NTERNATIONAL S TANDARDS  M ANUFACTURING C ONSIDERATIONS  E ASE O F S ERVICABILITY  W EIGHT F ACTORS  A ESTHETICS  C OSTS

Hydraulic Caliper C OMPONENT B REAKDOWN S YSTEM C OMPLETE S YSTEM Rotors & Hubs Mechanic Caliper Hydraulic Lever

H UB & R OTOR Design specification  U SE O F S EALED B EARINGS T HROUGHOUT F OR M AINTENANCE P URPOSES  C OMPATABLE W ITH S TANDARD Q UICK R ELEASES A ND 20mm T HROUGH A XLE S TANDARDS  T OOLESS D ISSASSEMBLY O F T HROUGH A XLE F OR W HEEL C HANGES A XLE F OR W HEEL C HANGES  M UST U SE H AYES R OTOR M OUNTING S TANDARD M OUNTING S TANDARD HOPE 20mm FRONT HUB

 L EVERAGE R ATIO S UITED T O S TANDARD V EE B RAKE L EVERS  P ROVIDE A DEQUATE B REAKING F ORCE  R EMOVABLE M ECHANISM  G IVE Z ERO P AD D RAG  P ERFORM R ELIABLY HAYES MECHANICAL CALIPER + ROTOR CALIPER + ROTOR M ECHANICAL C ALIPER D ESIGN S PECIFICATION

H YDRAULIC L EVERS  ERGONOMICAL DESIGN  OPEN BATH DESIGN  ROBUST DESIGN HOPE HYDRAULIC LEVER LEVER

H YDRAULIC D ISC  M UST U SE O PEN B ATH S YSTEM  P ROVIDE A DEQUATE B RAKING F ORCE B RAKING F ORCE  U SE R EADILY A VAILABLE A VAILABLE S EALS S EALS HAYES HYDRAULIC UNITS

M ATERIALS S ELECTION THE HUBS Al Alloy  LIGHT WEIGHT  HIGH STRENGTH  WEAR RESISTANCE  MACHINABILITY THE ROTORS - Carbon Fibre  THERMAL PROPERTIES  CORROSION RESISTANCE  COEFFICIENT OF FRICTION  WEIGHT HYDRAULIC FITTINGS Barrel inserts- Mild Steel Barrel inserts- Mild Steel  WEAR RESISTANCE  RIGIDITY Pistons - Brass Pistons - Brass  GOOD BEARING QUALITY CALIPER HOUSING Al Alloy  LIGHT WEIGHT  HIGH QUALITY SURFACE FINISH  HIGH RIGIDITY MECHANICAL FITTINGS - Mild Steel  HIGH STRENGTH  HIGH WEAR RESISTANCE

Rear hub assembly

Rear hub section

Rear hub explosion

Rotor center

Rotor assembly

Rotor explosion

Bearing explosion

Front hub assembly Front hub assembly

Front hub section

Front hub / through axle

Front hub section

Lever front view

Lever rear view

Wireframe view

Hydraulic Lever

Lever explosion

Lever section

How a hydraulic lever works

Caliper assembly

Wireframe views

interchangeable insert

Hydraulic insert

Mechanical insert

Caliper explosion

Caliper assembly

Full assembly