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My DIY rear disc brakes (step by step pics)
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JeffRobenolt
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PostPosted: Fri Feb 13, 2009 4:54 pm    Post subject: My DIY rear disc brakes (step by step pics) Reply with quote

Finally got the rears done.

I used calipers and vented rotors from an 91 Audi V8. These are found on a lot of early 90's Audi's with vented rotors.

The hubs are turned down and the stud holes were drilled 1mm larger for my NAPA longer studs there shoulder is 1mm larger than the stock vanagon studs. The studs hold the rotor centered.

Since I already have 15" alloys with the right ET, I didn't want to put a big spacer under the rotor.

It turned out good except I had to put five 1/16 washers, 1 on each stud to push the rotor out a little. I think with a little grinding on the bracket it will work without the washers.

The brake hose are bug lines from cip1.com. They are 10mm bubble flare, male on one end and female on the other. I ordered six 480mm lines. It took two lines per side on the rear and the other two lines are for the front.


Thanks to all the other post for all the great info and pushing me to finally do this.

Samba rocks!![/img]
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Last edited by JeffRobenolt on Mon Mar 02, 2009 10:35 am; edited 2 times in total
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mightyart
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PostPosted: Fri Feb 13, 2009 5:02 pm    Post subject: Reply with quote

http://www.thesamba.com/vw/forum/viewtopic.php?t=6
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levi
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PostPosted: Fri Feb 13, 2009 5:15 pm    Post subject: Reply with quote

so what was your total cost?
Have to re-locate your e-brake?
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JeffRobenolt
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PostPosted: Fri Feb 13, 2009 5:20 pm    Post subject: Reply with quote

some pics, thanks mightyart
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Any Q's you can PM me.
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JeffRobenolt
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PostPosted: Fri Feb 13, 2009 5:28 pm    Post subject: Reply with quote

I didn't do anything with the ebrake, mine is rusted solid. That's a project for another day.
It took three different designs before I found out this was the only way I could do it without a big spacer between the rotor and hub. So there was a lot of time into these, but now it wouldn't take 1/4 the time.

It's probably around a $100 for a pair.

Thanks Jeff
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JeffRobenolt
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PostPosted: Fri Feb 13, 2009 5:41 pm    Post subject: Reply with quote

Here is a list of cars that have these rear calipers.

C8484 is the part # at Autozone.

(Audi , 200 Quattro , 1989) Rear Right Wagon Exc. 20 Valve Eng. PREMIUM DISC BRAKE CALIPERS
C8484(Audi , 200 Quattro , 1990) Rear Right w/20 Valve Eng. PREMIUM DISC BRAKE CALIPERS
C8484(Audi , 100 Quattro , 1992) Rear Right Wagon Exc. 10 Valve Eng. PREMIUM DISC BRAKE CALIPERS
C8484(Audi , S4 , 1992) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , 100 Quattro , 1993) Rear Right Wagon Exc. 10 Valve Eng. PREMIUM DISC BRAKE CALIPERS
C8484(Audi , S4 , 1993) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , 100 Quattro , 1994) Rear Right Wagon Exc. 10 Valve Eng. PREMIUM DISC BRAKE CALIPERS
C8484(Audi , S4 , 1994) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , S6 , 1995) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , 200 Quattro , 1991) Rear Right w/20 Valve Eng. PREMIUM DISC BRAKE CALIPERS
C8484(Audi , V8 Quattro , 1990) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , V8 Quattro , 1991) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , V8 Quattro , 1992) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , V8 Quattro , 1993) Rear Right PREMIUM DISC BRAKE CALIPER
C8484(Audi , V8 Quattro , 1994) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , S6 , 1996) Rear Right PREMIUM DISC BRAKE CALIPERS
C8484(Audi , S6 , 1997) Rear Right PREMIUM DISC BRAKE CALIPERS
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D Clymer
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PostPosted: Fri Feb 13, 2009 6:21 pm    Post subject: Reply with quote

Looks good! You should be able to modify the e-brake cables to work with those calipers when the time comes.

FWIW, the vented 10.6" rear discs were only used on 1991 Audi 200 quattro 20Vs, 1990-1994 Audi V8s, 1992-1995 Audi S4/S6. The 5000 quattros, earlier 200 quattros, and C4 body 100 quattros all used smaller diameter non-vented rotors.


David
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presslab
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PostPosted: Fri Feb 13, 2009 8:36 pm    Post subject: Reply with quote

That's looking good, let us know how the e-brake works out.
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GrindGarage
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PostPosted: Sat Feb 14, 2009 7:00 am    Post subject: Reply with quote

Any chance that you would be able to provide a material list and drawing of your brackets?
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JeffRobenolt
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PostPosted: Sun Feb 15, 2009 7:03 pm    Post subject: Reply with quote

I'm hoping to do the install later this week and will take some pics and find the info.

Jeff
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PostPosted: Mon Mar 02, 2009 10:24 am    Post subject: Reply with quote

Here's some pics
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danfromsyr
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PostPosted: Mon Mar 02, 2009 6:51 pm    Post subject: Reply with quote

What rear Wheel studs did you use?

Do I HAVE to pay $8ea for 944 wheel studs for these rear disc setups?
I will be using some Audi alloy rims that do require longer stud setup.

Thanks
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JeffRobenolt
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PostPosted: Mon Mar 02, 2009 7:05 pm    Post subject: Reply with quote

I'll get the part # tomorrow.
They are Pretty cheap $2 or $3.
The knurl is 1mm larger than the stock lugs so you need to drill the hub.

It works out good because the larger knurl makes the Audi rotor center itself on the studs so you don't have to make a hub centric spacer.

Jeff
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PostPosted: Mon Mar 02, 2009 7:23 pm    Post subject: Reply with quote

Here is pics of the studs.
You can see the knurled shoulder sticks out of the hub to center the rotor.

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PostPosted: Mon Mar 02, 2009 8:40 pm    Post subject: Reply with quote

Looking good man! Thanks for all the pics. Now get that e-brake fixed and let me know how it works. Razz
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PostPosted: Wed Mar 04, 2009 10:07 pm    Post subject: Reply with quote

Anyword on what STUDS you used? what are the specs?
part #?
Size, diam, threads? over all length?
vehicle it belongs to?

I'd like to get out and pick up some.

Maybe I'll just order these from Small car? they'd be a press in no drilling fit.. but no rotor centering effect either.
http://www.smallcar.com/index.php?act=viewProd&productId=91

Vancafe sells 48mm in sets of 5 for $10
http://www.van-cafe.com/home/van/page_949_340/48_mm_wheel_studs.html
and alloy length wheel bolts for $2ea, $10/wheel
http://www.van-cafe.com/home/van/page_784

Thanks
Dan .

jrobewesty wrote:
Here is pics of the studs.
You can see the knurled shoulder sticks out of the hub to center the rotor.

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August 22/23/24 Westcott beach state park. (sites nearest the lake loop)
Sept 20/21 Moffitt beach DEC at Speculator, NY (sites 238-248 down on the end)
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PostPosted: Thu Mar 05, 2009 8:42 am    Post subject: Reply with quote

Does anyone have any idea on these conversion wheel studs?
or wouold you think the vanagon camper would just be far too heavy to take the risk?
BMW BENZ MB VW WHEEL STUD CONVERSION 14x1.5 - 12x1.5 Item#: 390031120573
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May 17/18 Chenango Valley SP (Pine Bluff loop) Sites 194-207
June 7/8 Grass Point state park (waters edge sites)
July 27/28 Sacandaga Campsite near Wells, NY DEC on the River. Sites# (61-70 between the rivers)
August 22/23/24 Westcott beach state park. (sites nearest the lake loop)
Sept 20/21 Moffitt beach DEC at Speculator, NY (sites 238-248 down on the end)
Oct 11/12 FAIRHAVEN State park for Fall sunsets over lake Ontario. Lakeview loop.
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PostPosted: Thu Mar 05, 2009 9:30 am    Post subject: Reply with quote

Sorry Dan.
Things have been a little crazy at home. The wife went into labor 3 weeks early. But all is good, a healthy baby boy.

The studs part # is,

Dorman 610-432,
length is 52.7
knurl 15.72(1mm larger than the stock ones)
shoulder 13.5mm.
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danfromsyr
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PostPosted: Thu Mar 05, 2009 1:21 pm    Post subject: Reply with quote

Hey man, that's quite OK.. and congrats.. and thanks.

the Audi 200 quattro (3B) rear rotos won't work with the subie calipers I have so I need to source some Eurovan rotors, but I am going to check the Syncro front rotors for a rear spot 1st.. if they are the right thickness and of course bolt pattern I may use those.
but will still need good studs to hold it all together.

jrobewesty wrote:
Sorry Dan.
Things have been a little crazy at home. The wife went into labor 3 weeks early. But all is good, a healthy baby boy.

The studs part # is,

Dorman 610-432,
length is 52.7
knurl 15.72(1mm larger than the stock ones)
shoulder 13.5mm.

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2019 Empire State VW camping events


May 17/18 Chenango Valley SP (Pine Bluff loop) Sites 194-207
June 7/8 Grass Point state park (waters edge sites)
July 27/28 Sacandaga Campsite near Wells, NY DEC on the River. Sites# (61-70 between the rivers)
August 22/23/24 Westcott beach state park. (sites nearest the lake loop)
Sept 20/21 Moffitt beach DEC at Speculator, NY (sites 238-248 down on the end)
Oct 11/12 FAIRHAVEN State park for Fall sunsets over lake Ontario. Lakeview loop.
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danfromsyr
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PostPosted: Fri Mar 06, 2009 9:33 am    Post subject: Reply with quote

JROBEWESTY, I did a little more internet digging on these so heres some more info.

The part# you listed is for a 99-97 Cadillac according to DORMAN wheel bolt catalog
but when I went to www.napaonline.com and tried ALL of the combinations of 97-99 Cadillacs they all are listed as 12mm x1.5 wheel studs. Isn't the vanagon 14mm?

jrobewesty wrote:
Sorry Dan.
Things have been a little crazy at home. The wife went into labor 3 weeks early. But all is good, a healthy baby boy.

The studs part # is,

Dorman 610-432,
length is 52.7
knurl 15.72(1mm larger than the stock ones)
shoulder 13.5mm.

_________________
2019 Empire State VW camping events


May 17/18 Chenango Valley SP (Pine Bluff loop) Sites 194-207
June 7/8 Grass Point state park (waters edge sites)
July 27/28 Sacandaga Campsite near Wells, NY DEC on the River. Sites# (61-70 between the rivers)
August 22/23/24 Westcott beach state park. (sites nearest the lake loop)
Sept 20/21 Moffitt beach DEC at Speculator, NY (sites 238-248 down on the end)
Oct 11/12 FAIRHAVEN State park for Fall sunsets over lake Ontario. Lakeview loop.
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