Rear Brake conversion

[bullstarz]

Just a splinter from my stag 1uzfe conversion.

It wasn't something i intended to do but had to in the end. I've used 280 mm disc and ford mondeo calipers. Main reason there're cheap. In the end I decided to get the brackets water jet cut out of 10 mm Alloy. My prototypes were usable but the redesign precise measurements was far better. If you are interested email for the file and format required, the designs can be moded for any caliper disc size.

[new to this]

Just a splinter from my stag 1uzfe conversion.

It wasn't something i intended to do but had to in the end. I've used 280 mm disc and ford mondeo calipers. Main reason there're cheap. In the end I decided to get the brackets water jet cut out of 10 mm Alloy. My prototypes were usable but the redesign precise measurements was far better. If you are interested email for the file and format required, the designs can be moded for any caliper disc size.


[ATTACH=CONFIG]25719[/ATTACH]

i was going to make one,but not got round to it yet ,why have you put so many holes in it ,is it for adjustment ? have you made up the cable and brackets for hand brake yet, does the caliper mount on the bracket with out any spacers,you said you used 280mm disc are they from the mondeo as well,i was going to use disc from rover 600 rears

dave

you could save me some time would you mind sending me the drawings thanks

[bullstarz]

Not a problem, what file type does your CAD program work with.

There's 6 holes on the swinging arm the extra 6 just give you more options when fitting. Calipers vary so much, even from each model year to year. As the holes are off the centre line just turning the bracket over given you 12 more fitting options. So you can get everything where you want.

I got the hand brake cables with the caliper, so I've used the ford one mated to the stags lever.

I used the disc from a Mazda 6, they are 114.3 but there're 5 stud not 4 stud. The rover 600 disc will need a few mm milling off the centre bore as the Stag is 69mm and Rovers 67mm (I think).

I just use the Mintex search to get the best suited disc. The best one for the standard set up, 4 stud, without machining is http://brakebook.com/bb/mintex/en_US...atasheet.xhtml.

[new to this]

Not a problem, what file type does your CAD program work with.

There's 6 holes on the swinging arm the extra 6 just give you more options when fitting. Calipers vary so much, even from each model year to year. As the holes are off the centre line just turning the bracket over given you 12 more fitting options. So you can get everything where you want.

I got the hand brake cables with the caliper, so I've used the ford one mated to the stags lever.

I used the disc from a Mazda 6, they are 114.3 but there're 5 stud not 4 stud. The rover 600 disc will need a few mm milling off the centre bore as the Stag is 69mm and Rovers 67mm (I think).

I just use the Mintex search to get the best suited disc. The best one for the standard set up, 4 stud, without machining is http://brakebook.com/bb/mintex/en_US...atasheet.xhtml.

not sure about CAD program im using windows 7 ,if not may we email me

two more questions 1 you said the backing plate was 10mm ally, are the studs on the trailing arm long enough,or have you use longer ones, i was going to use 6mm steel for backing plates same as monarch


2 the hand brake mech on the caliper is that at the top or bottom, ie have you fitted the left hand one on the right hand side etc,does the hand brake cable still run through the subframe arm, have you got any pictures of your set up please

thanks dave

[bullstarz]

There's free CAD programs on the net, the one i use is eMachineShop. Its good and free. Its good to keep the design on a CAD program as you can email the design to a machine shop. Which is then put in to a laser or water cutter. Once it's done they will post it out, it not as expensive as you might think.

Yes I had to replace the studs in the swinging arm. I was going to make it out of 6 mm steel, in fact the prototype was. The machine shop did have 6 mm plate but I was have other stuff made from 10 mm alloy. It save's money and time getting it all cut at the same time.

The hand brake cable is at the bottom of the caliper and can be run any where as the cable has an outer. I've took them off the car at the moment as it still being worked on and the new brackets haven't been posted yet.

[mjheathcote]

It's a while since I had the rear drum brake assembly in bits.
So you need the profiled mounting plate, which the caliper bolts too, the disc is the correct size to replace the redundant rear drum assembly, and that's it? Apart from sorting handbrake cable and brake lines.
Seems too simple, the profiled plate is the only custom fabrication required?

[new to this]

It's a while since I had the rear drum brake assembly in bits.
So you need the profiled mounting plate, which the caliper bolts too, the disc is the correct size to replace the redundant rear drum assembly, and that's it? Apart from sorting handbrake cable and brake lines.
Seems too simple, the profiled plate is the only custom fabrication required?

mike

i think so,you may also have to have a spacer on the back plate where it mounts to the caliper ?

dave

[bullstarz]

Yes the only part you need is the bracket, disc and caliper. You could pay over £500 for a "REAR DISC BRAKE CONVERSION KIT" or do it yourself for a fraction of the price.

The bracket will have to be amended depending on the disc/caliper used. The only other part you may need is a spacer on the hub if you can't get the clearance between the disc and caliper. Here's a few photos of another conversion, their bracket would require more machine work/expense. I do have their CAD file some where as well.

rd_5.JPGrd_4.JPGrd_1.JPGrd_2.JPGrd_3.JPG

.

I'll let you know how much the brackets cost to make, subsequent one's may be cheaper as they have all the measurement on their computer.

[Seaking]

TR6-Rear-Disc-Brakes-CD[1].jpgthis might be ok to use Dave

cheers glenn

[new to this]

[ATTACH=CONFIG]25819[/ATTACH]this might be ok to use Dave

cheers glenn

glenn

that one would not be right for the stag,the back plate should be about the same size as the disc,you need to protect the disc from stones etc,
i new some who had a disc shatter ones ( not a stag )

thanks dave

[Seaking]

Dave a thin metal plate disc size could be used as a seperate item to make things a bit eaiser.
cheers glenn

[new to this]

Dave a thin metal plate disc size could be used as a seperate item to make things a bit eaiser.
cheers glenn

glenn

good idea didn't think off that ,good job someones on the ball

dave

[bullstarz]

If you want that drawing i have that on cad as well, but it was designed for a TR. It will fit the stag if you use the same size disc and caliper. The photos in my last post are of that design.

You don't really need a back plate to protect the disc. My off road Rover went through all sorts of grief, sand, deep mud, snow, forests, moors, rivers, miles of green lanes and motorway and never had a problem. That went in some horrible places, good laugh though. The car's with backing plates actually caused problems with the build up of mud, stones, bits of trees and small fluffy mammals.

It would take a lot to shatter a disc, anyway it in side the wheel so there's very little chance of that happening.

[bullstarz]

Got the brackets back made out of some sort of alloy, 6082. Look good just need the time now to put them on. With 24 fitting options I should be able to get the best position for caliper clearance/brake hose/hand brake cable.


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