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post #1 of (permalink) Old 05-12-2003, 08:08 PM Thread Starter
 
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Converted to Rear Disc brakes

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This weekend I decided to do a disc brake conversion on the rear of my Samurai. This swap will only work with Toyota axles. I wasn't going to convert to rear discs, however after opening up the drums to replace the shoes there was no way I was going to mess with that rusted junk. I've always hated drum brakes anyway.

Costs:
The conversion cost me approximately CAD$200. I purchased rebuilt calipers, brand new rotors, and new brake pads.
1981 Monte Carlo Calipers: CAD$20.47
Caliper brake pads: CAD$23.99
1989 Chevy 4x4 pickup front rotors: CAD$55.89
2 of each of the above items are required.
I'll pick up brake hoses for next to nothing at the wrecker.

Chevy rotors
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Remove Toyota backing plate off bearing retainer.
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Reinstall bearing retainer on axle.
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I had to open up the center of the rotors using the lathe to fit the Toyota axles. If I remember correctly, the hole had to be opened up by 1/2".
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Like-new Monty Carlo calipers.
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Rotor machined to fit on axle. It is very important to machine the rotor evenly because the rotor uses it's center to center itself on the axle. It does not use the lug studs for centering purposes.
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Machined center
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I grinded a small amount of steel off the brake pads to allow them to clear the rotor better.
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This picture shows why I grinded the pads.
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Building the brackets is the most difficult part. I started off by making 2 plates, which are 4" long and 3/8" thick. I made these plates so they go up against the caliper body which will aid in holding the caliper in place under hard braking so all the force isn't on the mounting bolts. The mounting bolts have to thread into these 2 plates.
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This is the bottom part of the brackets - they are bolted to the axle housing utilizing the 4 - 3/8" bolts which hold the axle on. These plates are 3/8" thick steel.
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The plates have to be notched to clear the caliper body.
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Here are the finished passenger side brackets. The upper bracket and lower bracket plates are welded together.
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These are the upper bracket plates. I couldn't find a 7/8" fine thread tap, so I had to drill a hole, and weld a nut in them. Notice the tapered holes to allow for a strong weld.
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Drivers side brackets completed.
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Welded nut in plate as explained above
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Everything mounted up
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I didn't yet hook up the lines because I didn't have time to pick up some cheby hoses. My plan is to pick up some chevy hoses to connect to the calipers, and then reflare the hard line with a GM brake fitting. If not that, I'll pick up some GM to metric adapters.


anton
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post #2 of (permalink) Old 05-12-2003, 08:38 PM
 
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Re: Converted to Rear Disc brakes

Nice job on the conversion. I have converted Land Cruiser to rear disc brakes with GM parts. I used a different style bracket though. And had the caliper more towards the rear at an angle. i ended up spending about 300 bucks on my last conversion using all new parts... converting to 4 wheel disc brakes was the best money spent on that rig. (FJ55)
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post #3 of (permalink) Old 05-12-2003, 09:29 PM
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Re: Converted to Rear Disc brakes

Anton, when I did my rear disc brakes (using Eldorado calipers, same but with a parking brake) I used a stock front (banjo) rubber brake lines. Worked perfect, had them laying around so it was free and no adapters were needed.
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post #4 of (permalink) Old 05-12-2003, 10:45 PM Thread Starter
 
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Re: Converted to Rear Disc brakes

zooky - that's a good idea, I didn't think of using Suzuki lines on the GM calipers. I take it you had to use a GM banjo bolt or did the Suzuki one fit the Monte Carlo caliper?

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post #5 of (permalink) Old 05-13-2003, 05:09 AM
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Re: Converted to Rear Disc brakes

I used the GM bolt, it came with the caliper. Not sure if the sami one would work, probally not.
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post #6 of (permalink) Old 05-13-2003, 08:28 AM
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Re: Converted to Rear Disc brakes

Hey Anton, looking good. You Kung Fu is Strong!
I think it's great how your fab skills have improved over the few years you have been on the bbs that I have known you.
Keep up the good work! [img]images/graemlins/RockOn.gif[/img]
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post #7 of (permalink) Old 05-13-2003, 04:38 PM
 
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Re: Converted to Rear Disc brakes

I've said this before and I'll repeat it here: Anton's write-ups are better than most profesional magazine articles I've read. Good job!
[img]images/graemlins/goodpost.gif[/img] [img]images/graemlins/givemebeer.gif[/img]
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post #8 of (permalink) Old 05-13-2003, 04:40 PM
 
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Re: Converted to Rear Disc brakes

Once again nice work Anton. I guess it won't be long before you can "legally" drive it down the street. Did you get your learners permit yet?
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post #9 of (permalink) Old 05-13-2003, 05:45 PM
 
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Re: Converted to Rear Disc brakes

Anton - How long before you start selling that kit on ebay?

I have watched alot of the fab shops over the years, most of your fab skills are right up there with any of those guys, Now I'm waiting for you to build a web site and start selling some of your stuff.

[img]images/graemlins/RockOn.gif[/img] Now I need a mounting braket to put toyota p/s on the zuk.How much can you fix something up for me for ?
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post #10 of (permalink) Old 05-14-2003, 12:14 AM Thread Starter
 
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Re: Converted to Rear Disc brakes

Thanks for the nice comments.
Ray, I've had my Class 5 beginners for a few weeks now. It sure is great being able to drive on the road. My mom never gets to drive her car these days so long as I am around [img]images/graemlins/grin.gif[/img]

I just hooked up the brake hoses tonight. I took Zooky's advice on using stock Samurai front hoses, which worked just fine. The banjo bolts were the same size. I made up some nice little brackets to hold the hose in place, these were welded to the axle. It looks slick.

I took it for a drive down the road today. The brakes work great, however the pedal is a little soft and requires a couple pumps before it remains high. The shocks I ordered from Trail Tough will be here tomorrow so I'll have to haul ass to get everything done up by the weekend - I think I can swing it though.

Ray &amp; Roger, are either of you interested in going to Rennie for the weekend? It sounds like Art and I and some of his buddies will be heading out there for May long.

Sidetracker - There is so much I'd like to make and sell, however there is never enough time to do all of it. My truck is 45 minutes away, so I always forget to take measurments when I go to work on it. This makes it difficult for me to design/draw everything in CAD. When I have my truck in the city I should have more time to prefect the design of the brackets and draw them to have laser cut.
Anton
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