Braking new ground: In-house solution shows kaimahi ingenuity

By the Trades & Services Automotive Team

If you’ve wandered past the Mataaho automotive workshop lately, you might have spotted a shiny new bit of kit sitting proudly among the tool benches — our brand-new brake rig. It’s not just a shiny new toy; it’s a true product of Kiwi ingenuity, built from scratch by our very own automotive team: Zelalem Workneh, Brett Andreassen and Peter Smeets.

For years, our old brake rigs had been the backbone of the braking systems course. They’d seen generations of students come and go — each batch learning the mysteries of hydraulic systems, drum brakes and disc mechanisms through those faithful old machines.

But after more than two decades of service, time finally caught up with them. Hydraulic lines leaked, fittings corroded and spare parts were long discontinued. Keeping them going was a bit like patching up an old Holden with a bit of Number 8 wire.

Still, that didn’t stop our team from thinking, “We can do better.”

The spark of an idea

Rather than throwing in the towel (or a spanner), the team saw an opportunity to innovate. The plan? Build a brand-new braking simulator that could handle both modern disc brakes and the trusty drum setups still found in everyday cars — from the sleek Toyota hybrids on the road today to the hardworking Hilux utes that refuse to quit.

It wasn’t just about replacing the old rigs — it was about creating something smarter, stronger and easier to maintain. Something that truly reflected how today’s braking systems work.

From sketch to steel

Designing the new rig wasn’t a quick job. Every bolt, weld and bracket had to serve a purpose. The frame needed to be solid enough to handle repeated use yet compact enough to fit neatly in the workshop.

Once the plans were nailed down by technicians manager Brett Andreassen, our fabricator, automotive technician Peter Smeets fired up the welder and got to work shaping the steel skeleton.

Fellow technician Zelalem Workneh suggested using Toyota components for the build — reliable, easy to source, and perfect for the kind of hands-on learning we want our students to experience.

After a few trips to the wreckers and some careful selection, the parts came together. From there, Peter and Zelalem spent long hours assembling, refining and fine-tuning until the rig began to take shape.

When the prototype was finally unveiled, it turned heads straight away.

“This could change everything,” says vehicle systems lecturer Ian Green, watching as the system smoothly cycled through a demonstration.

For the first time, instructors could show — not just tell — how brake pressure moves through a system, what happens during bleeding, and how modern and traditional setups differ in performance. No more waving arms in the air trying to explain invisible hydraulics — the rig itself would do the talking.

Resourcefulness in action

As Peter put it, “We kept getting asked to fix the old rigs, but the parts just didn’t exist anymore. I looked online for overseas demo models, but they were ridiculously expensive. That’s when we thought — why not make our own?”

That “why not” moment was the turning point. Limited budget? No problem. Delays? Just another challenge. Between Peter’s planning, Zelalem’s precision and Brett’s technical insight, they powered through. The result is a unit that’s not only practical and cost-effective but built entirely in-house — a true showcase of Kiwi resourcefulness.

Zelalem summed it up perfectly: “It was a real team effort, and it shows what you can do with determination and teamwork, even when resources are tight.”

A hit with students

Even though it’s still in testing, the new rig has already become a talking point among students. Some have been caught peering through the workshop windows, curious about the new contraption. Others who’ve already completed their brakes course have admitted, with a bit of envy, that they wish it had been ready sooner.

Looking ahead

Maintaining and improving our training tools is an ongoing challenge, but one we’re proud to take on. Equipment like this doesn’t just make classes more engaging — it reflects the care, craftsmanship and commitment that define our training.

With this new brake rig, the automotive team has set the bar high for hands-on innovation. It’s a perfect example of what happens when Kiwi creativity meets mechanical know-how — proof that with a bit of determination, a few spare parts, and a lot of teamwork, you really can brake new ground.

All credit to the brilliant team behind the build: Zelalem, Peter and Brett — your ingenuity keeps our wheels turning.