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Difalco controller brake contact mod


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#1 dalek

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Posted 09 January 2018 - 06:39 AM

I have a Difalco controller and after I had used it for a year or so, the brakes became intermittent.  
 
After a few wall shots, I discovered that the brass plate on the back of the trigger had a spot that was black and pitted.
 
That plate and the screw head that it touches, is the controller's brake switch.
 
I went back and looked at the instructions and sure enough, it said to clean the plate periodically.
 
But after a while, the plate gets a low spot in it where it contacts the screw head.
 
The plate is relatively large.
 
Has anyone tried using a longer screw so the head could be raised and lowered in order to make contact at different points on the plate and different points on the side of the screw head?  
 
It would be like having a brand new brake switch each time you move it.  Make sense?
 
Also, maybe modify the screw hole so it's a slot so you could move the screw left and right for even more new points of contact?
 

Dale King
 
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#2 Mike Patterson

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Posted 09 January 2018 - 10:50 AM

I soldered a piece of brass tubing to the screw on mine. It gives more contact area, and is easier to clean than the screw head.


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#3 gotboostedvr6

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Posted 09 January 2018 - 11:05 AM

Increasing surface area of the brake contact may result in reduced breaking performance. If you do this without increasing the spring tension resistance across the circuit may actually increase.

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#4 Markomatic

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Posted 09 January 2018 - 11:06 AM

I have had the same issue with the full on contact that activates the relay. I keep them clean but sometimes when I go to full speed the car stops until I press the trigger harder. I was thinking of adding some micro switches in place of the contacts.


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#5 gotboostedvr6

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Posted 09 January 2018 - 11:09 AM

Leaving the brake contact in the stock configuration and cleaning it once a month would be a much simpler solution
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#6 Ramcatlarry

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Posted 09 January 2018 - 11:59 AM

Brass oxidizes.  Clean it well and TIN it with a coat of silver solder. Much less likely to oxidize.


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#7 wjtaylor

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Posted 09 January 2018 - 12:07 PM

If you are having a problem with intermittent brake issues, that is occasionally you will go sailing off into the corner and, no brakes! What I found was the tab that touches the brake button, over time bends and the button on the wiper arm moves further back until it actually is touching the brake band on the resistor and the trace behind it. I have now fixed 3 controllers, including one of mine, all having the same problem in operation and finding the same flaw. I simply rebent the tab and all 3 controllers stopped having the problem. Although I went out and bought a new DiFalco and don't use mine anymore


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#8 Greg VanPeenen

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Posted 09 January 2018 - 01:08 PM

Do what Larry said that has worked for me.



#9 JerseyJohn

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Posted 09 January 2018 - 06:41 PM

Quick fix flatten the brake contact screw allittle to increase contact. Permanent solution . purchase the parma full power and brake contact buttons with the mount and replace it. JJe8d107d6dce9f75179d2f844770ebc71.jpg?11577ed2aa243bd28521abb6db213e99e78.jpg?115 Koford also makes a silver button.


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#10 Greg VanPeenen

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Posted 09 January 2018 - 08:35 PM

Replace the whole works with a micro switch.


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