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buildyourown Samba Member
Joined: March 01, 2009 Posts: 1668 Location: Seattle
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Posted: Sun Mar 07, 2010 9:28 am Post subject: My big brake upgrade |
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Well, after 6 months of toiling on this 2 hrs at a time after work, in the dark, I'm just about done. Sorry for the pic quality, again, taken in the dark.
I've received an incredible amount of help from this forum, especially those that have gone before me. Thanks to all who helped.
The rears:
94-04 Ford Mustang Cobra caliper
94-04 Ford Mustang Cobra 296mm vented rotor.
Custom brake lines.
Home made adapter.
I chose these for a couple reasons. I liked the idea of a big enough rotor that I wouldn't have to turn the hubs. I'm not sure why since it isn't that hard. I wanted vented rears. I wanted a turnkey e-brake install.
Adapters for the calipers are nothing special. 1/2" cold roll steel machined to the right shape. I ended up with around .275" of total offset.
Fitting the rotors was easy. Open up the holes by 1/32" and they slip right on. They have a lot of offset to them though. I had to run my 16mm spacer behind the rotor to give some room for an adapter. Not an issue, as I already had spacers. I you were trying to fit ET30 wheels, you would have a problem. One advantage to that much offset, is the caliper is far enough outboard the access to the lower shock bolt is not an issue.
The brake lines I had done for me at a local hydraulic shop for $60/set. I was told that the lines off of a ~2000 Cadillac Eldorado would bolt right up. The picture looks right. I went to my NAPA and the guy said, why bother searching for lines when you can just have them made? Fair enough. They are a perfect fit and I'm pleased. Pacific Rubber for anybody in Seattle.
E-brake was the same as Loogy's. Turn the end of a piece of 4" long plumbing pipe to lengthen the cable housing. The cable itself is perfect.
Only thing left is to make a bracket to secure the brake line. It would probably be fine, but it won't hurt either.
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Christopher Schimke Samba Member
Joined: August 03, 2005 Posts: 5391 Location: PNW
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Posted: Sun Mar 07, 2010 9:38 am Post subject: |
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Nice job, man! Curious to know how you like them/how they perform for you.. _________________ "Sometimes you have to build a box to think outside of." - Bruce (not Springsteen)
*Custom wheel hardware for Audi/VW, Porsche and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected] |
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r39o Samba Polizei
Joined: May 18, 2005 Posts: 9800 Location: San Diego
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Posted: Sun Mar 07, 2010 10:43 am Post subject: Re: My big brake upgrade |
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buildyourown wrote: |
I chose these for a couple reasons. I liked the idea of a big enough rotor that I wouldn't have to turn the hubs. I'm not sure why since it isn't that hard. I wanted vented rears. I wanted a turnkey e-brake install. |
Because it is easy to do. Easy later to replicate. It is simple. It follows certain rules for retrofitting and updating. One of the main rules being change as little as possible.
I sort of put this rear brake thing on the back burner myself. I used Mercedes rotors in the front which slipped over the old hubs and want the same brand for the rear. No luck yet, but I have not looked in quite some time.
It is a nice job you did. Please let us know haw it works and any other details you need to adjust to make them work well. Thanks for sharing. _________________ "Use the SEARCH, Luke" But first visit the Vanagon FAQ!
1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....
Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently) |
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240Gordy Samba Member
Joined: May 15, 2008 Posts: 2354 Location: Vancouver, BC
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Posted: Sun Mar 07, 2010 10:57 am Post subject: |
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nice. love the way this works without machining, and Ford Mustang parts must be the most common aftermarket and performance parts now and in the future. a great future proof conversion. _________________ Tencentlife said,
"So, now that you know what you're doing, go to town."
2010 GOLF TRENDLINE 2.5
1985 GL now with more! a 2.1L
H&R SPORT(RED) Springs FRONT , SLAM SPECIALTIES RE6 AIRBAGS REAR |
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jeremysmithatshawdotca Samba Member
Joined: February 11, 2002 Posts: 2530 Location: Edmonton, AB
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Posted: Sun Mar 07, 2010 4:30 pm Post subject: Re: My big brake upgrade |
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buildyourown wrote: |
Adapters for the calipers are nothing special. 1/2" cold roll steel machined to the right shape. I ended up with around .275" of total offset. |
Any chance of posting a drawing? |
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ZimZam Samba Member
Joined: July 21, 2005 Posts: 562 Location: Talkeetna, AK
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Posted: Sun Mar 07, 2010 4:52 pm Post subject: |
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Bravo! Thanks for the beta. If you get a chance could you throw up a pic of the adapter. _________________ '85 Cabriolet (Margo)
'87 Westy (Heidi)
'75 Porsche 911S Targa
"Nobody trusts anyone, or why did they put tilt on a pinball machine.”
- Steve McQueen
"It's just metal, when rusted and dented , anything you will do will be better. Stop being afraid. What they (VW) did many year ago is not better then what you will do now." -Ben |
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buildyourown Samba Member
Joined: March 01, 2009 Posts: 1668 Location: Seattle
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Posted: Sun Mar 07, 2010 5:32 pm Post subject: |
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The adapter looks just like every other one posted on here so I didn't see a picture as being that informative.
But yes, I can throw some dimensions on it and post a screen shot. |
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r39o Samba Polizei
Joined: May 18, 2005 Posts: 9800 Location: San Diego
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Posted: Sun Mar 07, 2010 5:47 pm Post subject: |
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Is it the same one you can by from Burley? _________________ "Use the SEARCH, Luke" But first visit the Vanagon FAQ!
1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....
Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently) |
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buildyourown Samba Member
Joined: March 01, 2009 Posts: 1668 Location: Seattle
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Posted: Sun Mar 07, 2010 6:34 pm Post subject: |
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r39o wrote: |
Is it the same one you can by from Burley? |
No. I believe the Burley one uses Audi calipers and much smaller rotors.
I meant the same as in every other machined, homebuilt adapter is visually the same. |
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240Gordy Samba Member
Joined: May 15, 2008 Posts: 2354 Location: Vancouver, BC
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Posted: Sun Mar 07, 2010 6:50 pm Post subject: |
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buildyourown wrote: |
r39o wrote: |
Is it the same one you can by from Burley? |
No. I believe the Burley one uses Audi calipers and much smaller rotors.
I meant the same as in every other machined, homebuilt adapter is visually the same. |
don't be so modest. some of us are not quite so handy matching VW with Ford. _________________ Tencentlife said,
"So, now that you know what you're doing, go to town."
2010 GOLF TRENDLINE 2.5
1985 GL now with more! a 2.1L
H&R SPORT(RED) Springs FRONT , SLAM SPECIALTIES RE6 AIRBAGS REAR |
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r39o Samba Polizei
Joined: May 18, 2005 Posts: 9800 Location: San Diego
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Posted: Sun Mar 07, 2010 8:57 pm Post subject: |
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I was leaning towards the Mercedes 140 423 06 12 rotor as from an S420, but those Ford rotors are like $21. Hard to resist. Wonder if I can play games with the Burley brackets and get strictly buy and bolt on solution? Emmm...... _________________ "Use the SEARCH, Luke" But first visit the Vanagon FAQ!
1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....
Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently) |
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240Gordy Samba Member
Joined: May 15, 2008 Posts: 2354 Location: Vancouver, BC
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Posted: Sun Mar 07, 2010 9:00 pm Post subject: |
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what holds the rotor in place? just the wheel nuts? _________________ Tencentlife said,
"So, now that you know what you're doing, go to town."
2010 GOLF TRENDLINE 2.5
1985 GL now with more! a 2.1L
H&R SPORT(RED) Springs FRONT , SLAM SPECIALTIES RE6 AIRBAGS REAR |
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buildyourown Samba Member
Joined: March 01, 2009 Posts: 1668 Location: Seattle
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Posted: Sun Mar 07, 2010 9:33 pm Post subject: |
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240Gordy wrote: |
what holds the rotor in place? just the wheel nuts? |
Yeah, that's how most setups work. Once the bolts are to proper torque, the wheel / rotor/ hub /spacer will act as one piece. |
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buildyourown Samba Member
Joined: March 01, 2009 Posts: 1668 Location: Seattle
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Posted: Sun Mar 07, 2010 9:36 pm Post subject: |
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r39o wrote: |
I was leaning towards the Mercedes 140 423 06 12 rotor as from an S420, but those Ford rotors are like $21. Hard to resist. Wonder if I can play games with the Burley brackets and get strictly buy and bolt on solution? Emmm...... |
I don't think the Burley adapters would work at all with this big of a rotor. Your caliper position is going to be fixed and it won't fit over the rotor.
Don't make design decisions based on relatively cheap parts. If you save $100 and it takes 8 hrs of dicking around, how far ahead are you really? |
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240Gordy Samba Member
Joined: May 15, 2008 Posts: 2354 Location: Vancouver, BC
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Posted: Sun Mar 07, 2010 9:38 pm Post subject: |
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I thought so. The bolt pattern is a tad off, just making the holes a little bigger works okay, what is it a tenth of an inch?
I guess if someone was real picky one could have a shop machine a 5X112 pattern? _________________ Tencentlife said,
"So, now that you know what you're doing, go to town."
2010 GOLF TRENDLINE 2.5
1985 GL now with more! a 2.1L
H&R SPORT(RED) Springs FRONT , SLAM SPECIALTIES RE6 AIRBAGS REAR |
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buildyourown Samba Member
Joined: March 01, 2009 Posts: 1668 Location: Seattle
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Posted: Sun Mar 07, 2010 9:49 pm Post subject: |
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240Gordy wrote: |
I thought so. The bolt pattern is a tad off, just making the holes a little bigger works okay, what is it a tenth of an inch?
I guess if someone was real picky one could have a shop machine a 5X112 pattern? |
1/32" = .03125
I was planning on redrilling them when Loogy suggested opening up the holes. I figured I had nothing to loose. I could always still redrill them.
The are not scary at all. |
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240Gordy Samba Member
Joined: May 15, 2008 Posts: 2354 Location: Vancouver, BC
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Posted: Sun Mar 07, 2010 9:53 pm Post subject: |
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ah, Loogy. He's the little devil that sits on your shoulder and says "just do it!"
I mean that in a good way. _________________ Tencentlife said,
"So, now that you know what you're doing, go to town."
2010 GOLF TRENDLINE 2.5
1985 GL now with more! a 2.1L
H&R SPORT(RED) Springs FRONT , SLAM SPECIALTIES RE6 AIRBAGS REAR |
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Alaric.H Samba Member
Joined: March 28, 2009 Posts: 2529 Location: Sandy Springs GA
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Posted: Mon Mar 08, 2010 1:58 am Post subject: |
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How is the E brake clamping force I wonder if it is better with lager rotors. |
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mordeaux Samba Member
Joined: June 25, 2006 Posts: 249 Location: Mobtown
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Posted: Mon Mar 08, 2010 7:13 am Post subject: |
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Is this fitment based on larger diameter wheels or would it work with stock 14" alloys? |
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240Gordy Samba Member
Joined: May 15, 2008 Posts: 2354 Location: Vancouver, BC
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Posted: Mon Mar 08, 2010 8:35 am Post subject: |
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mordeaux wrote: |
Is this fitment based on larger diameter wheels or would it work with stock 14" alloys? |
the rotor in this conversion is 11.45667" _________________ Tencentlife said,
"So, now that you know what you're doing, go to town."
2010 GOLF TRENDLINE 2.5
1985 GL now with more! a 2.1L
H&R SPORT(RED) Springs FRONT , SLAM SPECIALTIES RE6 AIRBAGS REAR |
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