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"FAT" Dual Controls
Installation Instructions

A hardcopy of the installation instructions is provided with each kit we send. We provide you with the following transcript for viewing on-line.

You may also find that our Twin Stop web page on installations will provide some useful ideas and graphics. TS: Maintenance and Installation

FAT Dual Brake Installation Instructions

Due to the large variance in engineering and the numerous makes and models of cars available to North American consumers it would be very costly to engineer a dual control system that would readily bolt into any one application. For this reason it is up to the installer to use some creativity in installing this unit for its intended application.

(fig. 1) Dual Brake Nomenclature: Passenger Side
Instructor Brake Installation Instructions
A: Subassembly Of The Main Unit

Fasten the cable onto the pivot arm : The cable bolt needs to be threaded into the pivot arm just far enough so that the brake cable thimble end is still free to pivot. The cable bolt needs to be clamped tight onto the pivot arm using the lock nut : This way the brake cable thimble end is not clamped tight to the pivot arm and is allowed to pivot.

Thread the cable around the pulleys of the main unit according to (fig. 1) (see red parts). Thread the cable into the metal end of the cable housing and insert the cable housing metal end into the housing pulley block of the main unit.

B: Determining Position of the Main Unit And The Best Possible Cable Housing Path

Find a way to route the cable housing over to the driver’s side. Determine the best position for the main unit. The best position is usually as high on the firewall as possible, the limitation being the heater ducts, and as far to the right as possible, the limitation being the wheel well. Insert a pin into the carpet to mark the position of the upper mounting hole .

Depending on the floor angle and configuration of your vehicle it may be desirable to elevate the lower section of the base. This can be done by cutting and bending a piece of metal or putting a piece of wood that is the proper thickness under the bottom of the instructor's brake.

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(fig. 2) Dual Brake Nomenclature: Driver's Side
Instructor Brake Installation Instructions
(fig. 3) Alternative Pedal Clamp Installation For Vehicles With A “U” Shaped Or Plastic Type Brake Pedal Arm
Instructor Brake Installation Instructions
Page 2 of 4

(fig. 4) Clamp Position Options
Instructor Brake Installation Instructions
C: Fasten Clamp Assembly On The Brake Pedal

Fasten the Clamp Assembly on the cars brake pedal. (fig. 2 and fig. 4). The alternative clamp arm included in your kit can be used for vehicles with U shaped or plastic brake pedals. (fig. 3)

D: Determining A Good Position for The Driver's Side Floor Assembly

The Driver Side Floor Assembly should be positioned right or left so that the Pulley lines up with the clamp anvil . Also the Floor Assembly should be positioned up or down on the firewall so that it is in a good position to pull the brake pedal down. Turn the Floor Assembly so that the hole for the cable housing is pointed in the direction of the intended cable path that was determined in Part B

Part E: Review Positioning and Installation of Sections B, C, and D

Cable operated Dual Controls were designed to be a universal type of system however too many bends in the cable housing path is going to lead to a poorly operating system. You may consider compromising the positioning of Main Unit, Driver Side Floor Assembly and Clamp Assembly to achieve a less restrictive cable housing path. You will also need to plan out how the installation of the parts is going to be done. It’s likely that mounting, the two main parts in the positions that you want, is going to be a challenge. Vehicle components, particularly the steering column, is probably going to be in your way. Take into consideration what is on the bottom side of where you will be drilling your holes. It may be necessary to custom make a bracket by cutting, bending and drilling a blank piece of metal. This can be mounted in the vehicle with fasteners placed in workable, practical, and safe locations: The dual control part can then be mounted to this bracket.

Important Tip #1: When drilling holes start with a small drill, maybe 3/32: Drill carefully and don't allow the drill to pop excessively into the other side. It is going to be very difficult to determine what you are drilling into, especially for the first hole. Once the first hole is drilled, you can insert a piece of wire to carefully analyze where you are drilling; thus being assured of drilling the remaining holes safely.

F: Install Components and Complete Final Assembly

When finished installing the components, the cable housing will need to be fit between the stationary pulley block and the driver side Floor Assembly . The cable housing will need to be cut to the length needed. When determining the length of the cable housing , leave 1/2 of an inch to go into the stationary pulley block and 1/2 of an inch to go into the driver side Floor Assembly . Make sure the housing is not cut too short. It should be well seated into the hole at each end without being stretched. It is better the housing is a little longer than too short.

(fig. 5) Tie Housing Into Knot Before Cutting
Instructor Brake Installation Instructions
Before cutting the cable housing , tie it into a knot (fig. 5). This will cause the white nylon inner sleeve to retract into the housing. When the cut is complete, remove the knot and the sleeve will protrude back out. It’s important that the nylon sleeve inserts into the inner hole of the driver’s side Floor Assembly .

Fit the cut cable housing and route the cable through the main unit, the cable housing , the driver’s side floor assembly , the swage sleeve (if you put the swage sleeve on now it will be ready for the final assembly) and up into one side of the clamp anvil . Pull the cable through the clamp anvil to bring the instructors brake pedal into a desired up right position. Bring the end of the cable into the other side of the clamp anvil and tighten the anvil nut.
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G: Test The Dual Control

Test the dual control unit to make sure that it’s smoothly pulling the vehicles brake pedal down and allowing it to go back up when released. Make sure the brake lights are turning off when the brake pedal is released. In some cases, where the vehicles brake pedal does not have much spring-back force, an additional spring will need to be added. This spring would be stretched from the vehicle’s brake pedal to an anchor point under the vehicle’s dash. Brouwer Manufacturing Ltd. (dualbrake.com) does provide a spring for this purpose (item txiss), however, you should be able to find a suitable product at your local hardware store.

Important Tip #2: A small stretch cord (bungee cord) also works well as a substitute for this additional spring.

H: Install the Swage Sleeve

When the dual control is in proper working order, finish installing the swage sleeve as shown in (fig. 2). Use of this sleeve will aid in the cable pulling in-line with the center of the clamps swivel. A pair of pliers or vise grips can be used to crimp this sleeve.

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Attaching the accelerator: page one

1 original accelerator
2 small pulley-wheel
3 inner (2mm) accelerator cable
4 Fixing under carpet 5 Drilling 6 Using bolt and strip
7 existing bolt (example)

Dual Control Installation Determine the stroke of the accelerator (acc.) and position of the (small) pulley-wheel, make sure that the acc. will not be hindered and can move free.

If the stroke of the acc. does not allow the pulley-wheel to be placed under it: you can move it up or put it just on the side.

It is better not to pull to low on the acc. to avoid a long stroke on the accelerator on the dual control.
4 Fixing the small pulley wheel.
There are some options to fix the small pulley-wheel. The easiest way is to put the two L shaped strips behind the carpet if this is strong enough to keep the pulley-wheel in place when accelerating on the dual control. Slide the strip under the carpet, one to the right, the other to the left side.

5 An other option is to drill a small hole (3mm) and fix one of the L shaped strips to the floor with a self tapping screw, keep the pulley wheel above the carpet.

6 An option that is used often is to find an existing bolt close to the accelerator make and bend a strip from that point, to arrive at the point where you want the pulley- wheel to be. The longer the strip the thicker the steel you should use.

Attaching the accelerator: page two

Attach on dual controls side the cable thimble by hooking in on the accelerator.
The cable will stay in place but is easily detached when the car is privately used or in some counties during the exam it should be disabled.
Run the cable over the pulley wheel trough the Bowden cable to the small pulley wheel on the side of the original accelerator.

Dual Control Installation
Follow the instructions as in the clutch or brake cable fitting for adjusting of the length of the Bowden cable.
The small clip provided with the 2mm stainless steel cable is to be used to attach the cable on/through the accelerator.

Dual Control Installation

Sample of the attaching the cable to the accelerator pedal, note that if you pull low the stroke will be large on the dual controls side.
The accelerator pulley wheel on the dual control can also be fitted so that the bowden cable runs over in stead of under the dual control. Attach the pulley wheel and plate upside down to the dual control, adjust the direction of the cable attachment.
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