No problems. Let us know how it goes with fitting etc.
Cheers Rod:wasntme:
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No problems. Let us know how it goes with fitting etc.
Cheers Rod:wasntme:
Just an update on this: the Defender caliper fouls the hub so now we're looking at Golf calipers. Drat. Was hoping to keep this completely LR.
I finally got my heystee conversion bits. How's this....posted Friday afternoon in the Netherlands...arrived my doorstep Monday morning:). Very fast. Thanks FEDEX. Now comes the hard bit. getting the new bearings etc to put it all together. Will start a thread when I start assembly/ disassembly.
Cheers Rod:wasntme:
Hi guys. My Forbyn set of front conversion bits arrived last week. Very very nicely made - gleaming alloy just like in the pictures... I was up to my eyeballs in swivel grease last night dismantling everything :)
I meant to acquire a 90's D1 to raid for brake discs/calipers but somehow managed to get two of them! A 96 V8 4 dr and a 92 200tdi 2 dr, both with dodgy head gaskets. Spoiled for choice now :) We shall see which one will yields the right parts...
(hmm, one of them is still road legal for 3 months - maybe I'll chop the roof off with my new plasma cutter and use it as a open top...)
Photos and more will be added soon.
Hi, hows this conversion going now? I have all the parts for my heystee set up but I am seriously lacking the motivation atm.
Cheers Rod
Sent from my GT-P5110 using AULRO mobile app
Hi RodQuote:
Originally Posted by 67hardtop
As the original poster, I'll respond.
We are on the last stretch: Golf calipers were sourced, measurements were made, the caliper brackets were redesigned and the CAD image sent to the engineering shop to be re-cut.
We then realised we needed to replace front bearings. Then the Silly Season kicked in: most places closed here till 5 Jan.
That's sort of where it is at now, should be finished by the end of January God willing.
Then I'll test drive the vehicle for a few weeks to isolate any issues, and then we'll start marketing locally.
Hi thanks for the reply, I did a quick mock up with my heystee setup and all seems good BUT, seems like the disc mounting part of the hub isn't machined "true". will remove the disc and check hub for trueness on both disc face and wheel mount face, after I check if I installed the bearings correctly, and when I can get myself to doing it. bit of a motivation problem atm:(:(
good luck with it all.
Cheers Rod:wasntme:
Hi guys.
At last my installation of the Forbyn front disc conversion is complete!
The only major issues were mine ;) (a) having to get a crusty pair of front rotors and calipers from a late 80's 110 fully refurbished and (b) not being careful where I located the flexy brake hoses - resulting in one of them being destroyed :eek:
The kit arrived neatly packaged comprising: New swivel housings with seals and new hubs with bearing races already installed (I asked for new bearing rollers to be supplied as well so that they were matched).
Also supplied were thread locker (a nice touch) and sealant for the swivel seals; All necessary new bolts and cap screws included, plus an allen/hex key for the caliper bolts - of which more later...
Inexplicably included were two new massive road spring/shock mounting plates. A trial look/offering suggested that my standard early steel Disco1 rims and the 110 calipers would not foul anything on my original Series setup anywhere, so I left them on. Possibly other setups would need the new plates which set the shock mounts considerably further aft.
Two new flexy brake hoses were there. They had banjo fittings for the caliper and UNF fittings for the chassis end connections. All would have been well if I had not fully checked where they dangled ... as it was on my first run the starboard one rubbed on the rim and shagged it good and proper :o
Actually this was a good thing in the end. The NZ regs demand that replacement critical components are 'certified' or of known manufacture. I got new ones made up locally which are just that. Forbyn were helpful on that subject and did provide some documentation which might have given the USA ones a green light - but now I'll not know.
While you're doing the job, make sure you splash out on a full swivel bearing/Railko bush, stubs and shim kit. It was oh so nice to work on clean shiny bits! - and don't forget you'll also be needing axle tube oil seals, and seal runners for the stub axles - don't spoil the ship for a ha'porth of tar...
https://www.aulro.com/afvb/images/im...015/01/986.jpg
The kit as supplied. (When reading more below, come back to look at the stub axle bolt heads inside the swivel housing)
https://www.aulro.com/afvb/images/im...015/01/987.jpg
https://www.aulro.com/afvb/images/im...015/01/988.jpg
All this alloy work was very neat and looked professional.
Forbyn tell me : The castings are 356 aluminum heat treated to T6 and the billet hubs are 6061 aircraft alloy
https://www.aulro.com/afvb/images/im...015/01/989.jpg
A trial fit of the calipers. Note the very awkward angle on the hex key. This was a downside to the kit. Getting enough torks on them on the final fit was a nuisance.
I would now have removed the shocks to give better access all round.
https://www.aulro.com/afvb/images/im...015/01/990.jpg
Warning! Before fitting the rotor, make sure its mating surfaces are clean and smooth; otherwise it'll take some gentle persuasion to get them to fit properly.
https://www.aulro.com/afvb/images/im...015/01/991.jpg
Another little issue.. The bolts for the stub axle are pre-fitted. I checked they were fully screwed home but noticed that countersinking inside the swivel was not that deep. After I had bolted everything together, the new nylocs only just fitted. I used threadlock regardless. If you are using the kit, check the exposed bolt length first.
https://www.aulro.com/afvb/images/im...015/01/992.jpg
As is typical for Series swivels, setting up the preload was exasperating but we got there in the end. Those fancy digital fish scales were very handy..
https://www.aulro.com/afvb/images/im...015/01/993.jpg
All looks good in this shot :D
https://www.aulro.com/afvb/images/im...015/01/994.jpg
Watch out where you place the flexy hose. These original USA ones were 'straight' and thus I had to either have them up against the swivel housing or sticking upwards due to the LR casting thing (where, I think, dual circuit option hose would fit).
https://www.aulro.com/afvb/images/im...015/01/995.jpg
This is a new NZ made hose. I had a 20 degree bend put in the pipe - much easier to trial-error final placement.
https://www.aulro.com/afvb/images/im...015/01/996.jpg
and
https://www.aulro.com/afvb/images/im...015/01/997.jpg
Depending on the lead of the flexy pipes, you might find that you have to re-jig the chassis connector location. To keep mine clear of everything at all angles, I had to be creative and re-route the fixed brake lines.
And the results? - Ho hum.. my system is non-boosted and as I have read elsewhere, simply fitting discs will not automatically give you head-on-the-windscreen stopping power :( But, they are reliable, steady, do not give arse-wrinkling swerves left or right at the drop of a hat, and wonder of wonders, still work after plunging through mud and water..
My rotors were not pretty but still within tolerance. A new set would have been nice but the budget had been blown much earlier with refurbishing the calipers alone so...
All in all a good setup - and the disc bits are all standard LR so easy for replacing as and when needed.
Neil
you've gotten a lot further than I have. I will be using later model defender discs and calipers vented style front rotors on the front and solid on the rear. I have had a couple issues with the first mock up but will be dealing with them soon as I get my mojo back:(...lol. I wish I had gotten the forbyn bros kit. nice and shiney. The price I paid for new rotors here was about $200.00 for front and rear. I could have used the old rear ones but what the hell, I thought. strangely enough i'll be using the old brake pads coz they were only just replaced before the guy stacked the defender. Rolled it. swapped all his running gear into another defender so I got the f/r diffs cheap. original front rotors were only just in size so I opted for new ones. U should try to get a s3 booster and pedal assy for ur landy as the brakes will be AWESOME then.:D:D. great setup. good luck with it all....
Cheers Rod:wasntme:
Booster = yes... on the lookout right now! I had thought about late 90's Disco I brakes but re-jigging the whole braking system for dual circuit stuff with a booster was just too much. Plus the side issue of LR changing the caliper bolt holes' ID. Forbyn's kit is only, I think, for pre-1992 - but I didn't actually confirm..
Look forward to hearing/seeing how your own setup goes.