Brakes for Longboard

This project oversees the creation of brakes for a longboard. The implementation of these brakes is non-invasive, so there is no need to drill through the skateboard. This project also incorporates an LED light with functions such as turn signals, hazards, and a constant light to be used when braking. The light is operated by using a wireless handheld remote. The overall goal of this project is to increase the visibility and safety of the skateboard user to make stopping safer and to make the skateboard user more visible with the implementation of the light for nighttime use.

Materials:

• Longboard - x 1
• Weldable steel plate 6’’ x 24’’ - x 1
• Flat steel bar 1" x 3' - x 1
• Rubber block - x 1
• Corner brackets - x 2
• Brake light - x 1
• Zip ties - x 2
• Large bungee cord - 24" - x 1
• Small bungee cords - 10" - x 3
• Bolts, nuts, and lock washers - x 6 pairs

Tools:

• Drill
• Welder
• Cutoff wheel or hack saw
• Flathead screwdriver
• Ratchet wrench

Step 1: Measure and mark where you are going to drill on the rubber block. The corner brackets were used as a stencil to measure the drill points. Repeat this step for all 4 corners of the rubber block. These holes are for mounting the block to the sheet metal.

Drill the 4 holes. Next, use an exacto knife or a screwdriver to add a counter bore to each hole. This is so the bolt heads do not stick out past the rubber surface which would prevent braking.

Create 2 additional holes with counter bores. These will be used to mount the pedal.

Next, the sheet metal must be cut to size. The distance between the skateboard trucks was about 20-3/16 inches, so the middle was around 10.09 inches. With this in mind, the sheet metal was cut down to be 12 inches long (realistically, this length can be shorter). Afterwards, the metal was bent to accommodate the mount angle of the skateboard and then holes were marked and drilled to mount the assembly to the skateboard. Make sure the holes are out far enough towards the edge of the metal to accommodate the use of a bungee cord.

Next, mark and drill 6 holes that match those of the rubber block. Insert the bolts into the rubber block and the sheet metal.

Next, mount the 2 corner brackets and secure them using the bolts, washers, and nuts.

The next step is to make the pedal. The flat steel bar should be cut into 5 pieces, one measuring 9 inches, two measuring 6.25 inches, and the last two measuring 2-1/4 inches. The 9 inch piece is the pedal width, the 6.25 inch pieces are the "legs" that run vertically on either side of the skateboard, and the 2-1/4 inch pieces are the feet to mount the pedal to the brake assembly. Weld the pieces together so it makes a square "U" shape with feet that turn inward.

Once the welding is done, mark and drill where the feet will be mounted to the brake. Once the pedal is drilled, it is ready to be mounted to the brake assembly.

Next, mount the pedal to the assembly. This may be easiest by placing the brake assembly under the board, and then working the pedal around the skateboard. Once aligned, secure it to the brake assembly by using 2 pairs of bolts, washers, and nuts.

Next, add the three 10 inch bungee cords to the corner brackets. The bungees will help to pull up the brake assembly when not in use.

Next, use the 24 inch bungee cord to mount the brake assembly to the center of the skateboard. This can be done by hooking the bungee into one of the holes drilled into the sheet metal from earlier and wrapping it around the board as much as possible for maximum tension. As pictured, the bungee was hooked onto the board, as it did not reach the other hole in the sheet metal. This works too, just make sure it is hooked in a way that it is secure and won't slip off.

The final step is to mount the brake light. The brake light came with its own mount to mount it to a bike, which includes a rectangular rubber band that is then secured by a clip. Zip tie the brake light so it sits securely on the back of the truck (use however many zip ties needed, though for this project, 2 were used).

That's it! The skateboard brakes are now complete.