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On this page you will find pictures and know-how how to build a working stand for car ABS and sub systems.
On this page you will find pictures and know-how how to build a working stand for car ABS and sub systems.
There may be many different ways to do this, but overall layout would be always same.
There may be many different ways to do this, but overall layout would be always same.
If you are builiding a stand like this, there will be many possibilities to add/remove some functions, but our desingn allows to study passenger car ABS systems at the requiered level in vocational education.
If you are builiding a stand like this, there will be many possibilities to add/remove some functions, but our desingn allows to study passenger car ABS systems at the requiered level in vocational education.
Budget
Budget
Brakes/ ABS stand
Brakes/ ABS stand
Steel tubing ca. 60 kg 60.- Eur
Wheels with brakes 4pc 40.- Eur
Battery + battery switch + intelligent battery charger 160.- Eur
Braking system (master cylinder, vacum booster, ABS ECU and hydraulic unit, 4x steering knuckles with brake disc and caliper) 775-.Eur
Abs sensors - preferable (inductive, Hall and Mre) 150.- Eur
System to power up Hall and Mre (battery/V converter) 40.- Eur
Osciloscope and diagnostic device 800.- Eur
Brake lines, hoses(4x hose and 10m copper lines) 60.- Eur
4x pressure gauge to measure braking force 80.- Eur
Plexiglass/plastic 60.- Eur
Wires 20m 20.- Eur
Banana connections 30pc 40. -Eur
Additional materials (paint, nuts, polts, fasterners…) 80.-Eur
TOTAL: ca 2500 EUR
TOTAL: ca 2500 EUR
Please keep in mind that these are approximate prices. Most of them are purchased as used and therefore prices may vary a lot.
Additional materials:
Additional materials:
Drill set 80.-
Vernier calliper 40.-
Mechanic work lamp 40.-
Measure tape 20.-
Extension cord 5.-
Working gloves 15.-
Welding materials 20.-
Angle grinder discs 20.-
Protective glasses 5.-
Working clothes 80.-
Security boots 50.-
1. Prepare
1. Prepare
Things you need:
Things you need:
good planning
good planning
a car
a car
We use in our stand a scrapped Audi A6.
We use in our stand a scrapped Audi A6.
You also could use individual parts from different cars, but we decided to use only same car components, because then all electrical systems will comply to each other and we will be able to use diagnostic equipment to simulate faults.
You also could use individual parts from different cars, but we decided to use only same car components, because then all electrical systems will comply to each other and we will be able to use diagnostic equipment to simulate faults.
Also in the future we can add more diagnostic properties (engine, body electronic etc..) to make stand to one multistand wich can be used in many different lessons.
Also in the future we can add more diagnostic properties (engine, body electronic etc..) to make stand to one multistand wich can be used in many different lessons.
2. Cutting
2. Cutting
We cut our car in half. There were many reasons for that
We cut our car in half. There were many reasons for that
- rear was crashed so it was unusable anyway
- rear was crashed so it was unusable anyway
- future stand will take much less space (storage)
- future stand will take much less space (storage)
If you are cutting a car in half please follow all safety rules.
If you are cutting a car in half please follow all safety rules.
In car body there are many tensions, airbags, wires and hoses. Please ensure safety in all matters. If you are reading this instruction then hopefully you have all the knowledge to to this right.
In car body there are many tensions, airbags, wires and hoses. Please ensure safety in all matters. If you are reading this instruction then hopefully you have all the knowledge to to this right.
We use regular trolling cart wheels in our local handyman shop. Be aware to use stronger ones- ours can handle 220 kg each.
We use regular trolling cart wheels in our local handyman shop. Be aware to use stronger ones- ours can handle 220 kg each.
We use 30x25x3 steel tubing for our reinforcement. We do not provide any lenghts for that because all tube lenghts will vary for the car you use. Be sure to grind off all edges becauce they will be very sharp. We manage to cover most sharp edges with reinforcment bars.
We use 30x25x3 steel tubing for our reinforcement. We do not provide any lenghts for that because all tube lenghts will vary for the car you use. Be sure to grind off all edges becauce they will be very sharp. We manage to cover most sharp edges with reinforcment bars.
Things you need:
Things you need:
- angle grinder
- angle grinder
- cutting/grinding disks
- cutting/grinding disks
- tape
- tape
- measuring tape
- measuring tape
- marker pen
- marker pen
- safety goggles, gloves
- safety goggles, gloves
- garage jack (2-3)
- garage jack (2-3)
3. Frame for future panel
3. Frame for future panel
As for stand elecrtical panel frame we use same 30x25 tube. We made it aprox. 70x100 cm.
As for stand elecrtical panel frame we use same 30x25 tube. We made it aprox. 70x100 cm.
We use wooden plate as base for our panel so we drill already holes for future screws (wich hold panel in place)
We use wooden plate as base for our panel so we drill already holes for future screws (wich hold panel in place)
Also in picture you can find some steering knuckles with brake disk and calipers. We need them later but we already install them in this part of build.
Also in picture you can find some steering knuckles with brake disk and calipers. We need them later but we already install them in this part of build.
Also we use old Hynday bonnet lashes to make our frame little movable. So in future our wiring installation and maintenance/upgrade will be easyer.
Also we use old Hynday bonnet lashes to make our frame little movable. So in future our wiring installation and maintenance/upgrade will be easyer.
For safety please use some kind of planket/cardboard when grinding or welding a car. Sparks fly around and they are hot and can damage other car parts/interior or cause fire.
For safety please use some kind of planket/cardboard when grinding or welding a car. Sparks fly around and they are hot and can damage other car parts/interior or cause fire.
Things you need:
Things you need:
- angle grinder
- angle grinder
- cutting/grinding disks
- cutting/grinding disks
- tape
- tape
- measuring tape
- measuring tape
- marker pen
- marker pen
- safety goggles, gloves
- safety goggles, gloves
- welding mask
- welding mask
- welding equipment (we use mig/mag)
- welding equipment (we use mig/mag)
4. Prepare wooden plate
4. Prepare wooden plate
We use wooden 25mm thick and 100x100 cm plate as a base for our measuring panel. We choose wooden panel because there its easier to work with (drill holes, screws, saw it etc...)
We use wooden 25mm thick and 100x100 cm plate as a base for our measuring panel. We choose wooden panel because there its easier to work with (drill holes, screws, saw it etc...)
As alternative you can use MDF plate or some plastic plate.
As alternative you can use MDF plate or some plastic plate.
We also painted this plate 2x with hard outside window paint. So it will be esthetically beautiful and in future all electrical wire trails will be better visible.
We also painted this plate 2x with hard outside window paint. So it will be esthetically beautiful and in future all electrical wire trails will be better visible.
Things you need:
Things you need:
- wooden saw
- wooden saw
- wooden plate (ca 100x100 cm, min 20mm thick )
- wooden plate (ca 100x100 cm, min 20mm thick )
- paint brush
- paint brush
- measuring tape
- measuring tape
- 1l good white paint
- 1l good white paint
5. Plexiglass panel
5. Plexiglass panel
Things you need:
Things you need:
- plexiglass (900x900mm, 10mm thick)
- plexiglass (900x900mm, 10mm thick)
- measuring tape
- measuring tape
- soft blanket
- soft blanket
- 400 and up grit sandpaper to smoothen edges
- 400 and up grit sandpaper to smoothen edges
For our measuring panel we use 10mm plexiglass sheet.
For our measuring panel we use 10mm plexiglass sheet.
We decided that then our stand will be more attractive. Also it happens that we had exactly right size already in our garage.
We decided that then our stand will be more attractive. Also it happens that we had exactly right size already in our garage.
Plexiglass itself is clear, you can see it through. In picture it has its proctective film on it and thats why it seems blue.
Plexiglass itself is clear, you can see it through. In picture it has its proctective film on it and thats why it seems blue.
IMPORTANT: dont use hardened glass because you will not be able to cut it or drill holes in it.
IMPORTANT: dont use hardened glass because you will not be able to cut it or drill holes in it.
Also use soft blanket under glass werever you lay it. Proctective flim is very thin and otherwise you can scratch it easily.
Also use soft blanket under glass werever you lay it. Proctective flim is very thin and otherwise you can scratch it easily.
In picture we dont use that but we were aware of that and only lay it on hard surface to make picture.
In picture we dont use that but we were aware of that and only lay it on hard surface to make picture.
6. Wiring daigram sticker
6. Wiring daigram sticker
There are many options to make wiring diagram on plexiglass. We use opportunity to make a large sticker from Autodata wiring diagram.
There are many options to make wiring diagram on plexiglass. We use opportunity to make a large sticker from Autodata wiring diagram.
We save wiring diagram from Autodata as pdf and send it to our local advertising company. They charge us about 20 eur for 900x700 sticker.
We save wiring diagram from Autodata as pdf and send it to our local advertising company. They charge us about 20 eur for 900x700 sticker.
To lay sticker use 2-3 people. We use wet style (we spray water on the glass to make installation more easy)
To lay sticker use 2-3 people. We use wet style (we spray water on the glass to make installation more easy)
Maybe there is better way to do that but considering we are not proffessional sticker installers our result is more than satysfing.
Maybe there is better way to do that but considering we are not proffessional sticker installers our result is more than satysfing.
Our sticker was mirror style transparent sticker. So it is on the down side of plexiglass. This version benefit is that nobody touches real sticker and so paint and wiring diagram will be visible after long term on exploitation.
Our sticker was mirror style transparent sticker. So it is on the down side of plexiglass. This version benefit is that nobody touches real sticker and so paint and wiring diagram will be visible after long term on exploitation.
Things you need:
Things you need:
- steady hands
- steady hands
- water sprayer
- water sprayer
- soft rubbing gloth
- soft rubbing gloth
- rubber tool to wipe bubbles off (we use bank card)
- rubber tool to wipe bubbles off (we use bank card)
7. Banana connections
7. Banana connections
When choosing banana connections for the stand there are few things to consider.
When choosing banana connections for the stand there are few things to consider.
- They should be quite durable (students are using)
- They should be quite durable (students are using)
- in our case where we use 10mm thick plexiglass they must be long enough to reach threw plexiglass.
- in our case where we use 10mm thick plexiglass they must be long enough to reach threw plexiglass.
As effective they look, do not use metal connectors as they are potential hazard for short circuit!
As effective they look, do not use metal connectors as they are potential hazard for short circuit!
There are many colour options for the banana connectors. We use only red and black ones.
There are many colour options for the banana connectors. We use only red and black ones.
Reason for not to use different colours is to not make everything so clear to student. On a real car no connection is in different colour. Student have to find right wire to make measurments. Fot that he can use wiring diagram.
Reason for not to use different colours is to not make everything so clear to student. On a real car no connection is in different colour. Student have to find right wire to make measurments. Fot that he can use wiring diagram.
We use red on wires that have battery positive in all times and black ones in all other cases.
We use red on wires that have battery positive in all times and black ones in all other cases.
For drilling we use step drill. It makes very nice hole and phase around it.
For drilling we use step drill. It makes very nice hole and phase around it.
In lower picture you can see our first mistake. Do not make holes in the center of wiring crossroad. You have to have room for fitment and banana connections. Also pin numbers on ECU are more visible.
In lower picture you can see our first mistake. Do not make holes in the center of wiring crossroad. You have to have room for fitment and banana connections. Also pin numbers on ECU are more visible.
Things you need:
Things you need:
- drill
- drill
- step drill (6 to 18 mm)
- step drill (6 to 18 mm)
- banana connections
- banana connections
8. Installing plexiglass to base plate
8. Installing plexiglass to base plate
Lay your plexiglass to your wooden base and mark out places where you make holes for polts.
Lay your plexiglass to your wooden base and mark out places where you make holes for polts.
Use same step drill to make holes.
Use same step drill to make holes.
We use 15mm thick aluminium spacers. We had them as leftovers for lathe learning lessons. As alternative, you could use plastic or nuts.
We use 15mm thick aluminium spacers. We had them as leftovers for lathe learning lessons. As alternative, you could use plastic or nuts.
We put 3x3 pattern across sides and in the center and mostly used places 4 more.
We put 3x3 pattern across sides and in the center and mostly used places 4 more.
For fastening we use M6 furniture polts 55mm long. They has big flat head and they look nice.
For fastening we use M6 furniture polts 55mm long. They has big flat head and they look nice.
Things you need:
Things you need:
- drill
- drill
- step drill (6 to 18 mm)
- step drill (6 to 18 mm)
- about fourteen 15mm spacers
- about fourteen 15mm spacers
- same amount M6 polts with spacer and nut on the opposite side.
- same amount M6 polts with spacer and nut on the opposite side.
9. Installing wires
9. Installing wires
Image source: https://www.remybattery.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/f/e/female-disconnect-blue_1_1_1.jpg
As we use real car with its original wiring, we only have to make extensions for existing wires. For that we use 7 way 1mm2 cable.
As we use real car with its original wiring, we only have to make extensions for existing wires. For that we use 7 way 1mm2 cable.
To connect every wire to banana connector we use 2.5mm female wire connection.
To connect every wire to banana connector we use 2.5mm female wire connection.
Use only high quality ones, because they are much easyer to work with and they are also more flexible.
Use only high quality ones, because they are much easyer to work with and they are also more flexible.
Things you need:
Things you need:
- patience again
- patience again
- electrical pliers
- electrical pliers
- wire peeling pliers
- wire peeling pliers
- about 8m 7way 1mm2 wire.
- about 8m 7way 1mm2 wire.
Now make some room to connect all wire connections to banana connections.
Now make some room to connect all wire connections to banana connections.
When you lower plexiglass, all the wires will be in bundle. Thats ok, because you can pull them in nice order and tension at the other side of your wooden panel.
When you lower plexiglass, all the wires will be in bundle. Thats ok, because you can pull them in nice order and tension at the other side of your wooden panel.
As seen in lower picture.
As seen in lower picture.
Things you need:
Things you need:
2-3 persons
2-3 persons
10. "Ignition switch"
10. "Ignition switch"
To mimic car ignition switch we use ground switch. We also use digital voltmeter for battery voltage.
To mimic car ignition switch we use ground switch. We also use digital voltmeter for battery voltage.
Its useful because:
Its useful because:
- when its lightned all system is powered up (as ignition switch in real car)
- when its lightned all system is powered up (as ignition switch in real car)
- as we all know, when using diagnostic tool on a car you have to connect battery charger if voltage drops under 12V- student can observe this.
- as we all know, when using diagnostic tool on a car you have to connect battery charger if voltage drops under 12V- student can observe this.
We fasten "ignition switch" right on the wooden board, because this will be turned many times durning stand lifetime and plexiglass could broke.
We fasten "ignition switch" right on the wooden board, because this will be turned many times durning stand lifetime and plexiglass could broke.
Things you need:
Things you need:
- digital voltmeter (DC)
- digital voltmeter (DC)
- turnable ground switch
- turnable ground switch
11. Overall layout
11. Overall layout
We put connection places where in real life you would make measurments. When using plexiglass its wery easy to add more connections in future.
We put connection places where in real life you would make measurments. When using plexiglass its wery easy to add more connections in future.
In this picture, you can see that we also print on sticker colour coding for wires.
In this picture, you can see that we also print on sticker colour coding for wires.
In this and previous picture you can see OBD socket. We place it in the middle of panel because most of time we use KTS and the green box and laptop is on the table beside a stand. If we would put OBD connecror for example in the upper side of the panel then our diagnostic tool would have stay hanged and most probaly fall down several times.
In this and previous picture you can see OBD socket. We place it in the middle of panel because most of time we use KTS and the green box and laptop is on the table beside a stand. If we would put OBD connecror for example in the upper side of the panel then our diagnostic tool would have stay hanged and most probaly fall down several times.
Here you can see where it sits in a car/stand. We have enough room to add some brake related things on the side.
Here you can see where it sits in a car/stand. We have enough room to add some brake related things on the side.
12. Adding brakes, sensors ect...
12. Adding brakes, sensors ect...
Then we add original car brake calipers and discs. We also cut a little hole in the rear barking brake electric motor unit, so you could see parking brake activation and working principle.
Then we add original car brake calipers and discs. We also cut a little hole in the rear barking brake electric motor unit, so you could see parking brake activation and working principle.
We also add a handle, through which you can turn brake disc and simulate wheel spin. Future upgrade maybe will be to motorice this, but then belt/chain driven disc will also add a big safety risk and we must make pracautions to eliminate injuries. But that all will make real life "feeling" when looking parts fade away. So we use manual turning possibility.
We also add a handle, through which you can turn brake disc and simulate wheel spin. Future upgrade maybe will be to motorice this, but then belt/chain driven disc will also add a big safety risk and we must make pracautions to eliminate injuries. But that all will make real life "feeling" when looking parts fade away. So we use manual turning possibility.
Because our car uses hall type sensors for wheel speed signal, we add induction sensor also. To make it work, we found one old crnakshaft toothed wheel and we connect this to old car window motor.(you can activate it with switch on the left upper corner). Now we can simulate easily wheel spin and take measurments. Another important thing to keep in mind is how to attach sensor beside toothed ring- we use sheet metal, because its easy, but also we could simulate cap distance easilly with our thumb.
Because our car uses hall type sensors for wheel speed signal, we add induction sensor also. To make it work, we found one old crnakshaft toothed wheel and we connect this to old car window motor.(you can activate it with switch on the left upper corner). Now we can simulate easily wheel spin and take measurments. Another important thing to keep in mind is how to attach sensor beside toothed ring- we use sheet metal, because its easy, but also we could simulate cap distance easilly with our thumb.
20190216_150121.mp413. Adding QR codes
13. Adding QR codes
To make our stand more attractive and easy to use, we add QR codes for every topic in our e-learning materials. QR code is like "picture link"- you can take a picture from it with a special programme and then it will automatically quide you to right place. To make Qr codes, you can use many different easy online free programs- for example -
To make our stand more attractive and easy to use, we add QR codes for every topic in our e-learning materials. QR code is like "picture link"- you can take a picture from it with a special programme and then it will automatically quide you to right place. To make Qr codes, you can use many different easy online free programs- for example -
We print out them on sticker paper. Then we cower this paper with film (usually used as book covers)
We print out them on sticker paper. Then we cower this paper with film (usually used as book covers)
We add them on every important topic. Also for our projekt and our stand.
We add them on every important topic. Also for our projekt and our stand.
Like example- if you use some of these qr codes, you will be guided to vacum booster working principle wideo or DOT brake fluid boiling points.
Like example- if you use some of these qr codes, you will be guided to vacum booster working principle wideo or DOT brake fluid boiling points.
14. Final preparations
14. Final preparations
We print out Autodata wiring diagram for ABS system. Then we filmed it to make it durable. So students can learn wiring diagram reading skills and component finding.
We print out Autodata wiring diagram for ABS system. Then we filmed it to make it durable. So students can learn wiring diagram reading skills and component finding.
Because we use a real car for our base stand, we had a little time to make cutouts for other systems on the car. (doors, dashboard, seat)
Because we use a real car for our base stand, we had a little time to make cutouts for other systems on the car. (doors, dashboard, seat)
If everything was ready, we test our stand and all the connections. Because all stand was done by proffessionals, we didn't have any kind of problems.
If everything was ready, we test our stand and all the connections. Because all stand was done by proffessionals, we didn't have any kind of problems.
We like wery much that our stand is like a real car. All components are from real life and they work that way. That will give a real life experience for the student.
We like wery much that our stand is like a real car. All components are from real life and they work that way. That will give a real life experience for the student.
15. Outcome - stand is ready
15. Outcome - stand is ready
Our Stand came out like this. Of course there are several ways to do it. But the structure and logic of the base remain the same. However, our stand is definitely not ready, because we can add more worksheets and use different methodologies and approaches to solving tasks and problem situations.
Our Stand came out like this. Of course there are several ways to do it. But the structure and logic of the base remain the same. However, our stand is definitely not ready, because we can add more worksheets and use different methodologies and approaches to solving tasks and problem situations.
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