Handbrake Gaiter

[gromit]

Having got fed up with aftermarket Series gaiters that decompose in a very short period of time I decided to attempt to make a leather one.


The Problem (This is about 3 years old!)

https://www.aulro.com/afvb/images/imported/2015/10/1047.jpg (https://flic.kr/p/DzvE4G)DSCN3659 (https://flic.kr/p/DzvE4G) by Colin Radley (https://www.flickr.com/photos/152321353@N07/), on Flickr


Made aluminium templates to cut out a heavy leather 'washer' to stitch the gaiter to (also made a template for the Hi/Lo lever).

https://www.aulro.com/afvb/images/imported/2015/10/1048.jpg (https://flic.kr/p/21EzCtf)DSCN3660 (https://flic.kr/p/21EzCtf) by Colin Radley (https://www.flickr.com/photos/152321353@N07/), on Flickr


Punched the holes.

https://www.aulro.com/afvb/images/imported/2015/10/1049.jpg (https://flic.kr/p/21EzxLj)DSCN3667 (https://flic.kr/p/21EzxLj) by Colin Radley (https://www.flickr.com/photos/152321353@N07/), on Flickr


After trials with material, lots of templates made from cereal packets I cut some thin leather. I decided to make it from a single piece but it ends up a bit lop sided, MKII will be from two pieces so it's a bit more even.

https://www.aulro.com/afvb/images/imported/2015/10/1050.jpg (https://flic.kr/p/21Ezrpb)DSCN3662 (https://flic.kr/p/21Ezrpb) by Colin Radley (https://www.flickr.com/photos/152321353@N07/), on Flickr


The hard part was stitching the gaiter to the reinforcing washer. I used an industrial machine but manually turned because it was so fiddly.

https://www.aulro.com/afvb/images/imported/2015/10/1051.jpg (https://flic.kr/p/ZC7PWm)DSCN3663 (https://flic.kr/p/ZC7PWm) by Colin Radley (https://www.flickr.com/photos/152321353@N07/), on Flickr


Testing, I used an awl to start a hole in the thin leather for the self tappers.

https://www.aulro.com/afvb/images/imported/2015/10/1052.jpg (https://flic.kr/p/GLMhGT)DSCN3664 (https://flic.kr/p/GLMhGT) by Colin Radley (https://www.flickr.com/photos/152321353@N07/), on Flickr


Trial fitting. Under the seat a cable tie holds it tight to the handbrake lever.

https://www.aulro.com/afvb/images/imported/2015/10/1053.jpg (https://flic.kr/p/GLMsce)DSCN3665 (https://flic.kr/p/GLMsce) by Colin Radley (https://www.flickr.com/photos/152321353@N07/), on Flickr


A few changes for the MKII then I need to make templates for the Hi/Lo lever gaiter which will be made from two pieces of leather.

Not sure how it will last if it gets wet but I'll apply some neatsfoot oil to soften & waterproof the leather. Doesn't look out of place and better than the rubbish rubber ones.

Back to the shed.....



Colin

[whitehillbilly64]

Great Job, and looks the part.
When do you go into mass production ????
:)
whitehillbilly

[crackers]

I gather it's just an interference fit around the brake lever? Not tied in place or some other method.

Great idea. I will be attempting something similar with Wombat methinks.

[gromit]

Great Job, and looks the part.
When do you go into mass production ????
:)
whitehillbilly

At my hourly rate it would prove expensive....

The 'washers' really need to be die-cut, cutting using a knife round the template is a PITA.

Colin

[gromit]

I gather it's just an interference fit around the brake lever? Not tied in place or some other method.


The original rubber just slides over the handbrake lever, until it perishes & falls off......
The cable tie I used can easily be cut if you want to remove the leather gaiter.

Leather came from here Leffler Leather | Upholstery Leather | Cowhide Rugs | Saddle Leather | Leathercraft (http://www.leffler.com.au/) but it was from their bargain bin so you need to be a personal shopper.

Colin

[JDNSW]

I've thought of doing something like this myself, but the last rubbers I got (can't remember who from) have now lasted about six or seven years, so there does not seem to be any reason. Biggest problem I have had is with the rubber around the main gear lever.

John

[crackers]

I'm now tempted to paint the floor of the cabin a rusty colour and pattern... then put beautiful leather boots around the levers.

[Dark61]

brothers are doing it for themselves. Love it.


cheers,
D


p.s is there a collective name for a group of Land Rovers - or Land Rover owners?