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How to install your Bafang Hydraulic Disc Brake Sensors

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    #16
    Love it! Way to make that printer earn it's bench space!!
    Fabrication is fun! Build something today. Show someone. Let them help. Inspire and share. Spread the desire.

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      #17
      Just got the entire bbshd kit installed and everything works great except for the brake sensors. I can't seem to figure out a good way to mount them because my disk brakes travel such little distance when using them. Any ideas or suggestions are greatly appreciated!

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      • Jamie Gleeson
        Jamie Gleeson commented
        Editing a comment
        I have exactly the same promax dechiper brakes and have the same problem. It would help 2 people if there are any ideas to fix?

      • Mooonte
        Mooonte commented
        Editing a comment
        Hello. Have you found a good way of installing the sensors? Thanks!

      #18
      So, I did something a bit funky with some KYDEX sheets. As you can see in the photo, it's not pretty, but it was my first attempt. Basically, it's plastic that when heated will form to the shape you want when cooled. I cut it to the shape I thought I wanted and took a few tries to wrap the plastic around the magnet. My second try was much better and used no epoxy. I would cut up an old cotton tshirt into strips and wrap and tie as tight as I could while heating with a gun. I recommend another set of hands. I also recommend using a flat head screw driver to force down edges or push corners of the plastic into areas so that it grabs on to the brake lever. I know it's not pretty, but with a bit more patience and help, it could be quite good for those with no 3D printer. It took about 5 tries of testing on road before I settled to a point where it was consistent.

      The only reason the magnet is suspended instead of the obvious choice of maybe using the magnet on the brake lever, is because when I did that, it expanded the range of the magnet, this making it very difficult to find a spot for the sensor. Although, I think swapping their positions should work better for most. KYDEX is fun stuff, I'm sure I'll find more uses for it later.

      Link to the KYDEX I used. https://www.amazon.com/gp/product/B077S5N6TP

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        #19
        I use Sugru mouldable glue. Works awesome! :) I creates a silicon rubber bond. Comes in different colors and is easy to use. Mount both the magnet and sensor.

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          #20
          couple more, one side not done

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            #21
            Perhaps another option for the Avid Elixir system. Recently installed the Bafang BBSHD on my 2010 Specialized Stumper comp. The Luna kit was very 'plug and ride' with only two considerations. One was getting the best chainline and the other was finding a way to attach the Bafang brake sensor to the Avid/Elixir lever. What i ended up doing, which was pretty simple, was cutting a small bracket out of sheetmetal and using silicone adhesive to attach the sensor. Has worked fine. Hope a picture is truly worth a thousand words. Take care.
            Attached Files
            Last edited by mrgizmow; 12-14-2020, 04:54 PM.

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              #22
              Hot glue has worked well for me. One thing I have observed is the orientation of the magnet can make a difference. Put a mark on it so you can tell where it is then try different orientations. You will find some make it more sensitive and some less. May may all the difference in your mounting options or how you like to have yours adjusted. You can also get different magnets in different strengths that can give you different mounting options too.

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                #23
                My brake sensors have arrived.
                Unfortunately my DPC 18 display doesn't have a symbol to show me when the brake sensors are active, and I don't have a thumb throttle.
                Not quite sure how to best set myself up for the installation to work out where, and importantly how far apart to place the sensor and the magnet?

                I can't really fiddle around with the sensor position while pedalling....

                Any tips?

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                  #24
                  Originally posted by Letterman View Post
                  My brake sensors have arrived.
                  Unfortunately my DPC 18 display doesn't have a symbol to show me when the brake sensors are active, and I don't have a thumb throttle.
                  Not quite sure how to best set myself up for the installation to work out where, and importantly how far apart to place the sensor and the magnet?

                  I can't really fiddle around with the sensor position while pedalling....

                  Any tips?
                  Probe the brake sensor wire with voltmeter

                  Since you have two brake sensor connectors you can probe the connector for the one that isn't on the sensor you are trying to setup

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                    #25
                    Originally posted by AZguy View Post

                    Probe the brake sensor wire with voltmeter

                    Since you have two brake sensor connectors you can probe the connector for the one that isn't on the sensor you are trying to setup
                    Wow, I would never have thought of that, thank you!
                    I couldn't stop fiddling right after I made the post and managed to set up the sensors by putting the magnet at the most secure spot in the brake handle, and then just used tape to put the sensor in different positions. Ride, try the position, move the sensor and tape, try a new position, ride again, and so on.

                    A bit fiddly, but I'm very happy with the set up and sensitivity now.

                    And quite surprised how far apart the magnet and sensor have to be for the motor to disengage. Don't trust some of the Youtube videos where the put the sensor so close to the magnet that they are touching. For my sensor at least, I couldn't get the motor to disengage even with the brake lever fully pulled.


                    Thanks again for your clever idea though!

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                    • AZguy
                      AZguy commented
                      Editing a comment
                      I throw out ideas all the time and about one in ten of my ideas are pretty good LOL

                    #26
                    Sram brake sensor

                    This was my solution to stealthily and securely fitting a Hall effect brake sensor attachment to Sram guide lever. This would be suitable for types R, RS, RE, DB5. Perhaps RSC. A similar arrangement may be applicable to other brands of levers.

                    When I looked at the lever assembly there didn’t appear to be an easy, neat or really secure way to fix either the magnet or the sensor to the Sram Guide RE brake lever assembly on my electrified Boardman with Bafang BBS02, the reach adjustment of this lever really gets in the way and the master cylinder body has no decent flat surfaces.

                    My solution was to make a new pivot pin with integrated arm to hold the magnet. This way the sensor can be mounted with epoxy resin (having removed the sticky tape) on to the underside of the master cylinder, almost totally hidden from view and protected from damage. The pin and arm were made in the lathe from a solid piece of non magnetic stainless steel I had in stock. In my case I used a 3mm screw to retain the magnet but epoxy would do I’m sure.

                    In the Guide lever design the pivot pin is locked and retained to the piston push rod rocker assembly by a grub screw and as such the angle of the pin and thus the new arm is adjustable by loosening this screw, once set in position it is not effected by any change in angle set with the reach adjustment setting. This makes the subsequent setting up and locking of the sensing point relatively easy. An advantage being that no great precision is needed when fixing the sensor to the brake body as it is adjustable after assembly. Apart from the pivot pin diameter the dimensions are not critical, in my case dictated only by the size of the piece of stainless I had lying around. The pictures should make this clear I hope.

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