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Handbrake lever brackets - in situ repair


PACR

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My handbrake lever brackets have come adrift. Luckily this was when I was putting the handbrake on whilst stopping to fill up so was on a flat forecourt.

I've got the tunnel cover off (1999 de Dion so tunnel mounted lever) and it looks like I can clean up the small section tubes that brace the tunnel that the handbrake lever brackets were brazed to. I can then clean up the brackets, drill three holes on the mating faces and give exposed areas a coat of weld through primer. I can get a mig torch into the tunnel so three plug tacks through the holes per bracket can be made without much heat. I may be able to reassemble the brackets to the lever in the tunnel (had to unbolt to remove through the top) to hold in the right place for welding. Does this sound like the best solution without stripping out the propshaft or tunnel skins? Has anyone else done something easier / safer?

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Now all fixed. Pretty simple in the end. Plug welds do the job. I used a couple of washers to replicate the thickness of the handbrake lever mounting when tacking the brackets in place and alignment is spot on. I'd noticed my handbrake lever had been catching on my arm by not sitting down fully and an occasional clunking noisy when putting it on. I think a couple of the brazed spots must have been fractured for a while and the movement has overloaded the remaining until complete failure. If you try this keep an eye out for the fuel lines at the top of the tunnel.

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