But you do need help and a
few clues.
"I do
not think I really need trailer brakes on my camper as it is pretty light." is a comment I
get all the time.
Case
1:
Imagine
going down a mountain side on a dirt road with 2 tonne of Landcrusier and 750kg
unbraked (to keep it legal) camper. Hit the brakes for something as simple
as a corner and the Crusier skids on the dirt. You are into the corner still on
the skids and you take the foot off the brake and power around the corner. Done
that heaps of times I bet.
OK,
so you need trailer brakes right at this point. Now put a bit of rain on that
road and it's 10pm.
Case
2:
Boat
trailer towing from the Hawkesbury back to Brisbane, halfway down Cunningham’s
gap and two semis side by side and you are only doing 50'ks but the trucks are
going 20'ks. This one actually scared me enough to put disc rotors on my boat
trailer. Ended up locking all four disc brakes on the crusier, the front were
smokin, the boat was swaying and I was heading to the wrong side of the road
because I could not wipe of 30'ks before I hit the back of the
trucks.
Whether
your trailer is currently legal or not legal, brakes are a safety feature that
will get you out of trouble on most occasions. Too hard, too expensive, don’t
know much about brakes on trailers then read further.
OK,
enough said. You need brakes on your trailer if you are even thinking about
doing long trips.
10" Electric
conversion kits are usually fitted by trailer manufacturers or by trailer
repair centres. The weld ring (supplied) fits 125mm from the tip of the axle to
the front of the weld ring. In many cases the weld ring will fit on the last
round machine surface and will press hard against the shoulder should (non
machined surface). Axles up to 50mm Round or Square with Ford or Holden Bearings
will accept electric brakes.
Once
you have tacked the Brake Mounting Plate into position make sure it is
absolutely square and concentric with the axle. This is a critical step. If the
weld ring is out of square or not concentric with your axle then the Electric
Brake shoes will wear unevenly thus reducing braking efficiency.
Note:
Different axles use differrent mounting plates. 12" Electric brakes also use
different mounting plates. I have covered the popular models here.

Brake
Mount Plate – 73mm Hole Centres. Note: Electric Mount brake plates are different
to Hydraulic Brake Mount plates.
Fitting
the Electric brakes is a matter of tightening four nuts at the back of the Brake
Mount plate and then mounting 10” Drums and bearings.
There are two basic types of weld ring.
(a) Those that fit 45mm & 50mm axles and (b) those that fit 39mm and 40mm
axles
.
10" Electrics
have a rating of 1600kg when using 13” – 14” Ford or Holden wheels and 1450kg
when using 15” – 16” wheels. If you want 1600kg on 15” – 16” wheels then you
will need to go to 12” Electrics and 2 tonne drums.
Remember
to use 3mm cable or above when wiring your electric braking system. Often 2.5mm
or lower cable is used. These sizes are inadequate or marginal and provide
sufficient voltage drop from your battery to cause your brakes to work at
something lower than 100% capacity.
Example,
when using 2.5mm cable, your controller will be wound up to the max and
outputting maximum voltage. Voltage drop occurs at the point of the electric
brakes causing you to have only 50% braking capacity. Install 3mm cable or
larger and you see a much better result with very little voltage drop and
maximum power at your electric brakes.
If
you get stuck with this DIY installation give Steve or Des a call on 1800 753
731 and we'll help you through it.
It
is wise to have your trailer re-certified by an approved inspection station
after any DIY work.
______________________________________________________________________________
Difference
between Off Road, Highway and Budget Electric Brakes
(a)
Budget Electric Brakes are great for tandem trailers, horse floats and other
such trailers that perform short haul duties.
(b)
Standard Highway Electric Brakes are common on caravan and campers. Brake shoes
and magnets are of a higher grade to dissipate heat generated by long haul on
Australia's highways.
(c)
Off-Road driving can get hot and dusty. Normal duty electric brakes can get very
hot because dust, sand, etc builds up inside the Electric brakes. Off-Road
electric brakes have been designed to cater for the effects of off-road travel.
Better shoe material and stronger magnets make off-road brakes a must for the
serious traveller.
Off-Road
Magnets have plastic inserts to help prevent magnet wear caused by road
corrigations. The magnets rattle on the magnet actuation arm causing these arms
to fail if brakes are not fitted with Off-Road electric backing plates.
View Electric Brake Conversion Kits
View Marine Brake Conversion Kits
View Mechanical Brake Conversions

The above photo is a 1600kg Parallel set of Landcrusier
Drums.
BASICS
(legal stuff)
- Trailers
with a total ladened weight under 750kg generally do not need
brakes.
A fair amount of campers still prefer to put brakes on these lighter
trailers.
- Trailers
with a total ladened weight between 750kg - 2000kg need any type of brake on
one axle. Disc brakes, Mechanical drum brakes and electric brakes are common.
- Trailers
with a total ladened weight between 2000kg - 4500kg need electric brakes or electric/hydraulic on all axles
plus a breakaway kit.
- A
trailer is defined as anything that has wheels and is towed behind your
vehicle.
0kg to750kg Trailers
Generally
do not need brakes however you are permitted to put brakes on your trailer if it
makes you feel more comfortable and you plan to travel long distances. Brakes
may be required when towing according to your car manufacturers
recommendations.
750kg to 2000kg Trailers
- 10"
Disc rotors are the cheapest type of braking system you can install. You will
need to weld onto your axle a caliper mounting plate and the hard part is
over. If buying a new axle just ask your retailer to arrange for the calliper
anchor plate to be installed for you.
Disc
brakes are engaged by an override coupling that works when the vehicle brakes.
Simply, when the tow vehicle brakes, the trailer pushes into the tow vehicle and
activates the override assembly which pulls the cable attached to your disc
calipers. There is a small time delay with all override couplings. Commonly used
on boat and tandem trailers. Not recommended for camper trailers except if you
are doing a lot of sandy beach work..
- 9"
Mechanical Override brakes work the same as disc rotors except you need to
weld ring onto the axle to hold the mechanical brake backing plate. A little
more expensive than disc rotors and used by small caravans and trailers.
- 9"
Hydraulic Brakes work on an override assembly as above except the cable is
replaced with hydraulic lines. Mainly used on older caravans and tandem
trailers.
- 10"
Electric braking systems use a 4 hole weld ring to secure the 10" electric
backing plate to the axle. Once the electric backing plate is bolted to the
weld rings, the drum is then fitted and is secured with the axle nut. 10"
Electric brakes are suitable for axles up to 50mm in diameter. When tightening
your axle nut, tighten as much as possible then back of 1/8 turn.
- 12"
Electric braking systems are installed on axle’s sizes 50mm and above. Loads
over 1600kg on a single axle will require 12" braking systems.
Maximum
axle size for these system is 50mm. Ratings are 750kg/39mm Round Axle,
1000kg/40mm Square axle, 1500kg/45mm Square Axle.
Maximum
Tandem set-ups for 45mm are 2900kg with regard to 10" Electric Brakes. Over
2900kg on a tandem and you will require 12" Electrics.
2900kg
- 4500kg require 12" Electric Brakes on 50mm to 65mm Round depending on weight
requirements. Brakes on all axles + breakaway kit.
Once you have decided what weight you wish to carry then it is simply a matter of
selecting the axles, brakes and spring set-ups.
Most common set-up? Electric brakes on campers and caravans
by a long margin.
____________________________________________________________________________________
CLICK HERE: Some good advice on how to adjust brakes, bearings and general trailer setups from ALKO.
FAQ
Question: I am building a trailer and I want a complete set-up
under 750kg to go to Cape York.
Answer: Go for a 45mm Round axle rated
at 1450kg. Off-Road springs with 6 Stud lazy hubs. You can install brakes later if you
feel the need. A lower rated set-up will give you trouble because you will
almost certainly be carrying more than you think. Water, fuel, Food, gear, etc
will add more than you think to your total trailer
weight.
Question: My boat trailer is about 2 tonne tandem with 50mm Square
axles and brakes on all axles which do not work anymore. I purchased the trailer
and boat cheaply but the trailer needs work. I think I just need disc brakes on
one axle because the weight is pretty close to the
limit.
Answer: Together a trailer
and a boat will almost certainly weigh over 2 tonne unless you can get a weigh bridge certificate to prove it
otherwise. Nonetheless you will need one of these certificates anyway to get it registered in your name,
so I suggest that you weigh the rig so you are not throwing money at a
brake set-up that you may be required to change later. You’ll save a lot of
money in the long run by having the correct set-up the first time
around.
Question: I purchased a set of Electric brakes and had them
installed. The brakes do not lock the wheel when the brake controller is set to
full power.
Answer: (a) Check wiring to the electric
brakes and make sure the wiring is 3mm or larger. You may have a problem with
voltage drop. (b) The brake shoes may not have bedded themselves if you have not
travelled 100klms – 150 klms and re-adjust the brakes. (c) Apply 12volt directly
to the brakes, you will not be able to move the wheel. There may be a problem
with your electric brake controller if the direct method works
well.
Question: My
brakes are getting hot even when the shoes are backed right off and the
electrics are disconnected.
Answer: (a) Remove drum and inspect shoes.
Shoes must be concentrically aligned. One or both shoes may be out of centre.
Re-centre shoes and re-install drum. (b) Once drum is re-installed adjust shoes
until there is no more adjustment, then wind the adjustment lever 13 clicks. 13
clicks is the factory se |