Disc Brake Conversion.

**TJWA** · 11th August 2009, 10:47 AM

After much debate between me myself and I, I've decided to convert my front axle to disc brakes. I have considered the Zeus conversion but noticed it limits you to using Disco rims. Has anyone had any experience with other conversions?

**HBWC** · 11th August 2009, 10:54 AM

use the compleate diff asemble off your donner disco

**Psimpson7** · 11th August 2009, 10:55 AM

too wide, and wrong ratio!

**abaddonxi** · 11th August 2009, 11:02 AM

Several Series conversions discussed in The Good Oil - http://www.aulro.com/afvb/good-oil/5...-calipers.html

Cheers
Simon

**HBWC** · 11th August 2009, 11:36 AM

Originally Posted by Psimpson7

too wide, and wrong ratio!

hes changeing the ratios any way and whats wrong with a bit more track

**LandyAndy** · 11th August 2009, 07:52 PM

Johno has a point TJ.
Im sure it isnt IMPOSSIBLE to weld spring perches onto both your donor D1 axle housings.
The steering should be easily adapted.
The wider track is a bonous.
Andrew

**bcr2734** · 12th August 2009, 03:55 PM

it wouldn't be a series then would it? Has any one seen a conversion kit for overseas.

**Psimpson7** · 12th August 2009, 04:16 PM

The wider track wouldn't be a bonus! It would look daft for a start, and would drive I would suggest very badly

As a quick guide.

Defender / Disco casing between Swivel ball mounting faces: 1080mm

Series 3: 920mm

Defender track: 1511mm

Series 3: 1308mm

The difference is basically dead on 8 inches!!!!

IMO not a good idea.

**TJWA** · 12th August 2009, 09:43 PM

I'm thinking to overhaul my 3" drums and get them working as new I'm looking at $800 or more (the servo diagphram is stuffed). If I get a Zues kit I'm looking at $1800, BUT the 3" drums have 4 slave cylinders (more to go wrong and maintain), 30% less stopping power backwards, heaps more maintanance are effected by water and heating. I was hoping someone may have tried the Zues kit or other. I want to be able to bolt on the original rims or Discovery rims, I'm not sure I can do that with the Disco axles and it would be a lot more work than just bolting on a kit. I know you can't do that with the Zues kit so I may have to import something else.

I think this one could be the winner http://www.heystee-automotive.com/

**isuzurover** · 13th August 2009, 01:58 AM

Originally Posted by Psimpson7

The wider track wouldn't be a bonus! It would look daft for a start, and would drive I would suggest very badly

???

Does this look daft???

The above is a Series IIA with coiller axles. Looks fine to me, and I am sure it would drive fine...

Not sure where your numbers came from, but a SII/IIA/III axle is 55" WMS-WMS, a RRC/Disco1 is 61". So 6" difference.

The rear is easy, the front is a bit tricky in making sure the track rod doesn't foul on the springs - or you can get a late model swivel and move the track rod to the front, using a toyota-style combined track rod and drag link. Of course then you will have non ackerman steering, but it is apparently no big deal.

The above is by far the easiest and cheapest way to get disc brakes. The extra track width will increase stability on and off road, and increase wheel travel by a few inches at each end.

Apart from that, your options are either the TI console or Zeus conversions, or a custom setup using RRC components and custom caliper brackets. I have seen a couple of conversions using 2-piece caliper brackets which bolt to the top and bottom swivel pin brackets using specially made lengthened high strength studs.

Any of the above options will need engineering / blue plating to be legal.

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