Rear Discs

[Spikehaus]

I raised a thread a long time ago which discussed the the disc brake arrangement. This has however subsequently been deleted; but for the benefit of any new forum members I will raise a new one.

It basically says: Don't make the rear uprights to the book spec!!!! I have spent the last 5 hours milling and boring out the old welds from RU7 & RU8 plate!

Hope this saves someone the headache of what Dad and I went through today!

http://farm4.static.flickr.com/3485/3697602035_cac36cfb1d_m.jpg

Before

http://farm5.static.flickr.com/4052/4379500642_97b7777839_m.jpg

http://farm3.static.flickr.com/2723/4378749643_8e7932c0dd_m.jpg

http://farm3.static.flickr.com/2770/4378750343_387c38544a_m.jpg

[Bonzo]

That's looking a much better angle for the rear calipers Nick :) :cool:

I bet you had great fun seperating that plate from the upright .... Not :eek: :D

[deezee]

What exactly is wrong with the book design? Are we talking about the 1st revision orientation issue, or another issue?

[flyerncle]

Caliper hits the shock mount.

[Spikehaus]

This is what we eventually levered off after milling of all the weld.....

http://farm5.static.flickr.com/4012/4379501686_fcf92bec35_m.jpg

The second revision book specification is still wrong for this item, or at least it is for a standard sierra brake caliper!

[flyerncle]

Nick,did you ever get the ally seat made ?.

[Spikehaus]

http://farm5.static.flickr.com/4049/4291318802_1da42047be_m.jpg

They just need fitting and a few holes of harness. Then its all comfort and cosmetic work

[flyerncle]

Nice one Nick ,looking good.:cool:

[Matthew]

Arrgh!

I wish I'd seen this earlier as I have a set of rear uprights made to book spec, and until today I hadn't thought to offer up the caliper. Looking at it one option could be to swap the assembly to the other side. The bleed nipple would end up at the bottom, but apart from that it looks like it could work.

Did you try that? If you did were there other problems?

Matt

[Spikehaus]

I tried it in almost every position I could think off! The main issue is that the calliper cannot run freely in any position without either the handbrake cable or the brake pipe fowling on the lower wishbone.

I am not sure how you will modify it if you do not have the correct tools, it took dad and I 4 hours and that was using a Pro 3000 Mill MX2 mill. Hope you find a way to get round it.

[Matthew]

I bought the made up version from 3GE so I don't even have the jig to align everything if I did manage to get it apart.

I'll give them a call on Monday and see what they think - sounds like it may be cheaper to get a new pair than to pay someone to disassemble and re-weld the existing ones.

Can you do me a favour and let me know the exact angle that the plates need to be at.

Thanks
Matt

[RAYLEE29]

Hi, mine are set at 45 degrees rearward from the upright like yours spike
handbrake cable runs nicely to caliper just need to cut off end and shorten inner cable
planning on a bracket hanging between upper wishbone mounts to keep cable out of the way of wishbones
no pics at mo if anyone wants pics ill take some
Ray:)

[Spikehaus]

Matt

I will not be in the workshop where the car lives again now until Saturday, so will do it then. I pretty much just lined the RU8 plate right hand upper hole to align vertically to the upright. (Just remember to make each one a reverse so each other) I am sure 3GE can make you a new one. As for the old ones, stick them on e bay. You are sure to sell it super quick. .

[Spikehaus]

Matt

I forgot to say, I also have a reason why I want to wait till the weekend.....I am starting a 14 week AutoCAD course that starts tomorrow night. So this will be my first project to be able to send you a CAD drawing! Its about time I put my design skills onto paper!

[Matthew]

Thanks

There's no hurry, I won't have time to do anything on the car until the weekend either.

Good luck with the course.

Matt

[twinturbo]

Matt

I forgot to say, I also have a reason why I want to wait till the weekend.....I am starting a 14 week AutoCAD course that starts tomorrow night. So this will be my first project to be able to send you a CAD drawing! Its about time I put my design skills onto paper!

I did AutoCad at uni back in 1992, I guess it's moved on abit ( except in how much it costs :eek: )

TT

[adrianreeve]

Just thought I'd let people who have already made their disc rear uprights according to the book, that all is not lost! My standard sierra callipers fitted upside down, no problem, and a disc handbrake cable from Westfield at £22 fits perfectly without any cutting! Happy days!

Only problem is that the bleed nipple is at the bottom of the calliper, but if you can build a car, I reckon you can probably work out how to bleed the upside down calliper!

Cheers

Adrian

[teun]

Great news i will change left/right at this moment i have no place for the cable i see if your idea will work thanks.

[Spikehaus]

Well done Adrian, I did not try it in that position! Are you using disc guards as well? I have not forgotten about the CAD drawing. I am on week four of the Autocad evening course so I can now turn the PC on and Login! Will you have finished your car before I finish the 18 week course?? haha

[adrianreeve]

Spike

No, not using the disc guards. It all fits together really well without, and I'm really glad, coz I didn't want to pay out for more uprights!

Cheers

Adrian

[carlknight1982]

been watching this with intrest as im fitting up my brakes this weekend!

did you use the seight cable of the westfield shop adrian?

[adrianreeve]

Carl

Sorry, I forgot to reply to this one! I used the seiw one at £22. I found that if you fit it to the plate at the rear o the tranny tunnel, then cross the cables over so they make an x over the diff, then the cable ends fit onto the calipers perfectly. I've used rubber lined p clips to secure the outer cables to the top of the chassis rails above the rear suspension. I've madeit sound much more complicated than it is, if you get the cable in your hands, it just kind of falls into place. By the way, I took dogwood's advice and slotted the holes in the mounting plate, meaning you can fit the cable much easier, and without having to cut it. Hope that helps.

Adrian

[Josh]

Oh bugger... I've just red this!!!!!!!! I brought my rear uprights from 3GE over a year ago now, had no idea....

What are my options? I have access to a decent milling machine so cutting the welds off *could* be done but its a huge amount of effort :eek:

Could just buy new ones with the right angle and suffer the cost... :(

Is there deffinatly no way it can be done with the plates as per the book in the vertical position?

Josh

[Bonzo]

Hi Josh

3GE do a drum to disc brake adapter plate

3GE disc adapter (http://www.3gecomponents.com/templates1/view_product.php?product=510&site=63&department=118)

This may help you to work around your problem :)

[james3004]

I think someonse said you can mount them upside down on opposite sides?

[Tony]

I was searcing the web for the exact same problem, I have hit lucky though, my uprights were from AS motorsport, and they are slightly different design, the mounting plate portion is totally round, so I have found that I can just rotate my bearing carrier to the desired position, punch, drill, and tap, et voila I get the calipers in a better position

couldnt for the life of me work out how on earth you got that handbrake cable to route and actually work in the designed way of the book, not that the book covers much regarding the braking section anyway :(

[Matthew]

Oh bugger... I've just red this!!!!!!!! I brought my rear uprights from 3GE over a year ago now, had no idea....

What are my options? I have access to a decent milling machine so cutting the welds off *could* be done but its a huge amount of effort :eek:

Could just buy new ones with the right angle and suffer the cost... :(

Is there deffinatly no way it can be done with the plates as per the book in the vertical position?

Josh

Exactly the problem I had - and I bought a new set from 3GE as I didn't fancy mounting the calipers upside down. Now all I need to do is find someone who'd like to buy a set of the book spec ones.

Matt

[twinturbo]

couldnt for the life of me work out how on earth you got that handbrake cable to route and actually work in the designed way of the book, not that the book covers much regarding the braking section anyway :(

does the book car use drums?

TT

[carlknight1982]

yeah the book car uses rear drums

[drury318]

The book car uses drums & if you use the same setup from the donor, with perhaps smaller wheel cyls from an escort as I did, you shouldn`t have any problems with brake distribution. The Iva tester who checked mine said everything calculated spot on, not that I could decipher it, he also added that a common problem is people using rear brakes that are TOO good,typically rear discs, thus upsetting the distribution figures etc. I can only imagine the trouble you may have trying to check whether your brakes are too good or not good enough at home, or even worse to sort out a fail afterwards. I took the view it was hard enough to pass the IVA anyway without making it harder for myself, best to keep it simple and modify later if you must.
Dennis

[mark]

Can i just add to this my car went through iva fine with drums on the back too and the brakes are very very good for fast road use

Drums do look rubbish :rolleyes: but on such a light car they do the job fine

[Headshot]

Apparently disks are common on the back of most cars due to costs and ease of balancing ABS systems :confused:

(I'll be using drums, just a set of mintex shoes and away you go :) )

[Johnnybizzle]

I did mine to the book, ive just put my rear caliper up side down works a treat, harder to bleed but handbrake cable is at the top as it should be

regards Jon