BUGA Community
Technical => Driveline => Disk Brakes => Topic started by: Warren on May 27, 2011, 01:58:43 PM
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I feel that the work RestoReid has been doing on his camper is excellent.
I particularly like the Diff & Disc brake conversion how too's so I have decided to give them there own thread
It will be all Reids words without the chatter and hopefully will be a good reference for the future - hope you don't mind Reid.
take it away Reid
Well guys some more picks of my suspension & brake upgrade A armes cleaned & painted new bushes & balljoints
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3197;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3199;image)
Parts for brake conversion VH commie hubs VX commie discs hats VJ twin piston calipers
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3201;image)
Cutting the discs off the hubs with angle grinder Yes Ben I was real careful
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3203;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3205;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3207;image)
Now the machining starts to get the hats to fit the hubs
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3209;image)
I have already got the new bearings & seals for the hubs Only got to get steel plates for caliper bracketsw will post more as I get it done Cheers Reid.
Here are the difference between VH & VX discs
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3260;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3262;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3264;image)
Have had 1 hub turned down to fit inside VX disc hat for mock up purposes
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3266;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3268;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3270;image)
Made a template out of masonite for the caliper bracket
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3272;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3274;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3276;image)
Had to grinde the casting flashes & about 1mm off here to allow the caliper to come back far enough to get full pad contact with disc
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3278;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3280;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3282;image)
Well that's about it for now till I get some more machining done I think it's coming togeather pritty good Cheers Reid
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3284;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3286;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3288;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3290;image)
The main inner bearing is XE Falcon fits strait in no machining the outer bearing will be machined out for bedford size same as the old castlemain kit easy as Cheers Reid
Done a little more machining today Turned down outside diameter to fit inside disc hat & machined 3mm off the face so the spiggot came through enough for wheel to locate Next job to machine out outside bearing
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=3313;image)
Well guys I got a heap more done this week finished machining the hubs drilled & tapped the caliper brackets & trial fitted it all up needed 4mm spacer between the caliper & the plate to center the caliper up on the disc is all done & painted & will install tomorrow sorry no pics here their in my gallery Will get some more as I fit them up Cheers Reid
Things youl need to make the brackets
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29767&g2_serialNumber=2)
Very back yardish but it does the job
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29772&g2_serialNumber=2)
Made up centering plug to get the bolt holes spot on
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29777&g2_serialNumber=2)
Startin to look store bought
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29782&g2_serialNumber=2)
Machining all done
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29787&g2_serialNumber=2)
All painted ready to go on
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29792&g2_serialNumber=2)
Caliper brackets had 4mm spacer to center caliper on disc
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29797&g2_serialNumber=2)
Caliper bracket on with new unbreako bolts
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29820&g2_serialNumber=2)
From the back
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29825&g2_serialNumber=2)
Hub on with new bearings & 10mm longer wheel studs
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29830&g2_serialNumber=2)
Almost looks profesional
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29835&g2_serialNumber=2)
Disc on
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29840&g2_serialNumber=2)
From behind
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29845&g2_serialNumber=2)
Caliper holder on Have to clean up & paint yet
(http://www.buga.com.au/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=29850&g2_serialNumber=2)
Had a good day finally starting to piece it togeather Photos worth a 1000 words
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4300;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4302;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4304;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4306;image)
Some more
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4308;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4310;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4312;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4314;image)
And some more only have to fit brake hose & make grease cap & job done Cheers Reid
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4316;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4318;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4320;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4322;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4324;image)
Hi guys Here is a photo off finished front discs conversion all that's needed is a 2inch dust cap or ill have to make an adaptor to fit a holden one
Other photo for those that are interested is the non return valve in standard bedford master cylinder which I belive has to be removed when discs are installed Cheers Reid
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4383;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4385;image)
Well guy's finally got it going & took it for a lap on thursday arvo Left the nonreturn valves out Not happy the pedal nearly went to the floor before brakes started to work so back up on jack stands all wheels off & had a head scratch what to do so I put the nonreturn valves back in they are plastic spring loaded & have a small bleed hole in the centre Gave the whole system a good pleed Wife came in handy there got a fair bit of air out Put wheels back on & went for another lap FANTASTIC best thing ive done to it sofar Just have to find some 2inch dust caps & job finished By the way the front track 'center of tyre to center of tyre only increased by 5mm at 1670 mm over standard bedford real happy with that steering will be NO heavier Anyway enough for now Cheers Reid
Well took the camper out for a good run today Man what a difference the brakes are excellent getting better as the pads bed in I was worried that the 3.08 diff as going to be too high but it is perfect will cruse at 100ks easy at 2800rpm & still got plenty of pickup left Its much quieter inside without the old noisy diff & it uses 2nd gear more which is good before it hardley used 2nd would go streight to top with the old 3.70 diff With all the new suspension parts & neww shocks it's gone from a shitbox to a LIMO & im as happy as a pig in shit Cheers Reid
Well another week gone & finally finished the brakes Took me 2 days to make dust caps for front hubs couldnt finde any that were2inch but they prob wouldnt it anyway Made up first one out off 2inch exaust pipe put it on & tried to put wheel on & it poped the center cap off the wag Binned it & made another had to be big enough to go over hub nut & small enough to go inside mag wheel took 2days bitch of a job but finished now take her for a spin into port tomorrow Cheers Reid
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4630;image)
(http://www.buga.com.au/index.php?option=com_smf&Itemid=2&action=dlattach;topic=453.0;attach=4632;image)
Went for a nice long drive into Port Macquarie today camper went great smooth as & the brakes work fantastic it's a totally different thing to drive still got a few attles to chase down but not too bad John you hit the nail on the head Finding someone to do the job is the problem there are shops in the cities that spcalise in these conversions but they charge a leg & arm & the smaller shops dont want to know about it & private blokes are a bit wairy about doing conversions like this for other people that's why I did it myself My brother in law lives next door he is a certified welder & has a smell laith so between us we had the gear to do the job Only had to farm out the machining of the outside bearing as his laith was too small to hold the hub without it jumping out & that cost me $50 It seams the Hopper stopper BA falcon kit would be the best & I think it's about $2500 & I think a diff would cost about $1500 you supply the diff I couldnt find anybody around here that was interested in doing the job & my b inlaw had done quite a few diffs for himself so it was easy & I nutted out the front brakes myself & got him to do most of the machining on the hubs & the rest was easy That's why I put so many picks up so others could see how I done it & maby they could find somewone to help with welding & machining Anything else you would like to know just ask & ill help if I can Cheers Reid
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Ok I have unlocked this so that people can ask questions and Reid can respond
Any off topic or chat pots will be deleted to keep the thread clean
Warren
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By the way fellers there are a few photos off the diff & the brake calliper bracket construction on pages 5 - 6 in my gallery for some reason they wouldnt load in the posts so I put them in my gallery Cheers Reid
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Reid
I have added the pics from your gallery
Warren
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All i can say is i wish i had that sort of engineering nouse, awesome stuff reid. I do a lot of welding, but doing this sort of work i would be worried about my welds failing, or the hub not being true or centered, so i have a lot of respect for guys that can get stuck into that sort of work.
I like the idea of setting this up for everyone to read, ever thought of doing a dvd, start to finish on how to build a disc brake conversion. Just a thought. ;) ;) ;) ;D ;D ;D :o :o :o
george
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George
The only welding in this conversion is on the calliper spacers, and that could have been left out, as once the spacers are in place they are held together by the bolts.
Welding them in place just make it easier when assembing the callipers.
Warren
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Yes George Warren is spot on ya gotta make servicing as easy as possable & if I had just used washers your bound to leave one out George the only welding was on the diff conversion & my broinlaw who is a welder by trade done it all for me cause im hopless at welding I leave all those special jobs to the specialests Cheers Reid
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Awesome conversion Reid and a great reference article for anyone else to follow. Even if you don't have the gear to do the job yourself you could use this reference to show a machine shop what's involved and make them feel happy that they could handle it. Great effort and well done.
Garry.
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Hi caspar here. Ive been very interested in your disc brake conversion. I was wondering if you did all for corners or just the front brakes? I have a 1977 lwb camper and would love to put 4 discs on. Can you help with anymore info. What you have up has been great to read.
Cheers
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Hi casper Glad you liked my conversion The disc brake diff is in the diff section Now your LWB is a whole different ball game they being a 6 bolt hub & dual wheel diff I would love to have a go at one but would need to sit & stare at one for a few days & work out if the front hub could be used or maby a F100 or some other 6bolt hub could be used Im sure it could be done but I dont know about the diff If it was mine Iwould keep the 6bolt stud pattern & put some of thoes cool truck wheels on Would look fat Where are you at It would be great to talk & try to work out something Cheers Reid
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Hi there.. It has currently had the rear dual wheels replaced with singles if thats any help. I'm currently in Tas at the moment but organize something. I have big plans for it and am serious about doing it right. It wiill still be at least 6-12 months before I start major work on the beast but want to gather as much info as possible. I would love to see your van sometime
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Awesome post, Hey restoreid, i did a castlemaine disc brake conversion and no matter what we do, the pedal is still spongy - i've even taken it to a brake specialist with only minor improvement - still running the same master and booster with an in line proportioning valve..............any suggestions??
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Sorry I havent got back to you guys earlier But I have just had eye surgery & cant see a bloddy thing Go Getter Tasy a we are supposed to be over there right now but it wasnt to be next year hopefully Is the diff a bedford or something else It is best to keep the front & rear brakes off the same model car Thats why my diff is VR to match the VR front discs The booster & master cylinder are standard beddie & work great
Mezz Dont know wats going on there I had that trouble at first but a good bleed fixed that Start at the wheel the furtherest from the master cylinder which would be pas rear then driv rear then pas front then driv front maby that proporting valve is shutting off when you pump the peddle up & not letting flued through to the rear wheels Had that trouble with a Mini years ago & just opened up the valve in each rear wheel & slowly pumped the pedal till all the air was gone Give that a try & see how it goes Cheers Blind Reid
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Awesome post, Hey restoreid, i did a castlemaine disc brake conversion and no matter what we do, the pedal is still spongy - i've even taken it to a brake specialist with only minor improvement - still running the same master and booster with an in line proportioning valve..............any suggestions??[/quote
if the bore is too small on the master cylinder it will be spoungy.. i, not sure what standard is. id look at enlarging the bore to a 1inch bore?
ben
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I think the bore in the beddie is 1inch