The control and actuation system

Here is a view of the innards of the brake enclosure. The Hydrastar is mounted in the center. The brake line connection is in the back, and protrudes through the back of the enclosure. The battery box is to the upper right of the Hydrastar. To the lower right of the Hydrastar is the custom brake fluid funnel which fits absolutely perfect. Made from an old spray bottle and stored in a plastic cup. Bridged over the lower section of the Hydrastar is the lid fastening stud and retainer. The retainer is actually about 3/4" away from the Hydrastar. I made it from a media retainer they threw out at work. Bending the retainer at the pre-made holes made it turn out perfect, and it was already primed. To the left of the Hydrastar are the many wiring connections where the trailer umbilical cord passes through the enclosure. The onboard battery charger sits down low in that area. I have it wired so the interior dome light runs off the charged battery, so I can use the light anytime.

The studs securing the aluminum channel are visible here. Rubber weatherstripping runs along the top face of the channel. A piece of leftover conduit holds up the lid for now. A better system is being thought of. The top of the conduit rests on the bottom side of the tapped bolt that secures the knob in the lid.

Also note all the rust on the frame. You probably couldnt miss it. The paint was so thin that it started rusting the day I brought the trailer home. When the weather gets nice, I plan on repainting the whole frame with some thick Rustoleum.

Here is a view of the brake controller in the tow car. Not a very good picture but all my closeups turned out blurry. The controller is a Tekonsha Envoy, which applies power to the Hydrastar in a way that is proportional to how hard the car is trying to stop. I used the standard mounting bracket, along with a piece of stainless steel and a piece of aluminum channel to mount the controller to my console without drilling. The wires are run into the console, under the carpet, and to the dash. Wow what a job, considering that I did it in a snowstorm. Around here, you cant let the weather get you down or you wont get anything done.

Heres another view of the stainless bracket I made to attach the controller to the console. The visible bracket is not screwed to the console, but is screwed to the piece of channel. The channel fits perfectly to the shape of the console construction, and is sandwiched between the upper and lower console halves. The lower extension of the visible bracket keeps the controller from wanting to move downward. I like the controller in this location. I can reach it very easily and without looking. It doesnt block my heater duct, cupholders, or get in my way. Its just perfect.