Series disc brake conversion --- I did it my way

Nice, nice work. And I can just imagine how much work was involved.

I'd hate to think about engineering it over here - especially way up here - but a kit that came with some sort of approval from an engineer would be worth paying for. At least I'd be able to show them that yes, someone else thinks it's okay.

Pictured below is what some Stage I owners have used to reduce the rear brake effect, (I think it's a Disco part), when they put Zeus discs on the front of theirs. I almost got a Zeus kit. Too bad they were so disorganised they couldn't actually get a quote to me!

http://www.aulro.com/afvb/attachment...1&d=1361796441

After a great deal of thought and after liaison with my Accountant, Solicitor and Certifying Engineer, I have decided that this conversion will be offered for sale via 2 methods:

a) A complete drive-in / drive-out conversion, where all components are fitted by myself, in my workshop. This will include an Engineering Certificate for each individual vehicle. This will also include upgrading to Series 3 dual circuit pedal box, master cylinder, brake fail switch and the 8 inch dual diaphram booster, as well as fitting new rear wheel cylinders, regardless of model. SWB versions will also require the fitting of 11 inch rear brake assemblies. In other words, the brakes will be upgraded to exactly what is fitted to my series 3.

b) A complete pre-assembled kit of all components necessary to complete the conversion. Some items will be on an exchange basis. The exchanged items will have to be serviceable and of the correct type or a core charge will apply. The kit will include the front components pre-assembled, so that all that is required for fitting is to disconnect the front brake hoses, disconnect the tie rod ends, undo 6 bolts on either end of the axle housing, and bolt on the new assemblies. A pedal box will be included pre-fitted with the booster and master cylinder. The kit form will also be available as an outright purchase, without the need to exchange any items. I will be happy to supply a COPY of my Engineering Certificate to assist you with arranging your own certification.

Prices will vary somewhat depending on the model and if you have reclaimable items to exchange. A preliminary price guide appears below.

The high braking performance achieved through this conversion is due to the superior design of the calipers, the increased booster assistance, the overall brake balance and also the choice of disc pad compound. Any attempt to mix other components will upset the braking balance and performance. Anyone seriously considering upgrading their brakes is encouraged to come and drive my vehicle. The results are astonishing.

Cookey

Brake Conversion Pricing


Conversion parts

2 x reconditioned 4 piston aluminium calipers @ 225-00 $450-00
2 x modified 276mm vented rotors @ 125-00 $250-00
1 x premium grade disc pad set (Bendix Ultimate) @ 160-00 $160-00
2 x fabricated caliper mounting bracket @ 250-00 $500-00
2 x modified swivel housings (exchange – core charge $50 ea) @ 60-00 $120-00
2 x modified wheel hub (exchange – corecharge$50ea) @ 60-00 $120-00
2 x modified brake drum spacers (exchange – core charge $20 ea) @ 25-00 $ 50-00
1 x modified pedal box (series 3 type) (exchange – core charge $100) @ 100-00 $100-00
2 x caliper steel brake pipes @ 15-00 $ 30-00
1 x 8” dual diaphram booster @ 140-00 $140-00
2 x master cylinder extended steel brake pipes @ 25-00 $ 50-00
2 x rear wheel cylinder @ 40-00 $ 80-00
1 x various sundries, lock tabs, nuts, bolts, etc. @ 50-00 $ 50-00
2 x railco bush to bearing conversion @ 75-00 $150-00

Total $ 2250-00



Additional items if required

1 x brake master cylinder (dual circuit) $ 275-00
2 x wheel bearing and seal kit @ $90-00 $ 180-00
2 x swivel ball seals @ $35-00 $ 70-00
2 x lower swivel pin bearings @ $25-00 $ 50-00
2 x servicable stub axles @ $25-00 $ 50-00
2 x servicable swivel balls @ $95-00 $ 190-00
2 x servicable front axle shafts @ $95-00 $ 190-00
2 x serviceable rear brake drums @ $50-00 $ 100-00
1 x set rear brake shoes $ 85-00
1 x dual circuit pressure differential valve & switch (series 3 type) $ 100-00
1 x warning lamp modification (if required) $ 100-00




Fitting service

Series 2-2a $ 825-00
Series 3 (single circuit) $ 715-00
Series 3 (dual circuit) $ 550-00
Stage 1 V8 $ 550-00



Engineering Certificate $ 660-00



Note: all prices include GST where applicable

Sounds great. I think the price is realistic for what you get, and comparable to something like a gearbox rebuild and so on - in other words, it's a big job for you to put the kit together.

I think you're going to need a website!

Quote:

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Originally Posted by cookey

b) A complete pre-assembled kit of all components necessary to complete the conversion. Some items will be on an exchange basis. The exchanged items will have to be serviceable and of the correct type or a core charge will apply. The kit will include the front components pre-assembled, so that all that is required for fitting is to disconnect the front brake hoses, disconnect the tie rod ends, undo 6 bolts on either end of the axle housing, and bolt on the new assemblies. A pedal box will be included pre-fitted with the booster and master cylinder. The kit form will also be available as an outright purchase, without the need to exchange any items. I will be happy to supply a COPY of my Engineering Certificate to assist you with arranging your own certification.

Prices will vary somewhat depending on the model and if you have reclaimable items to exchange. A preliminary price guide appears below.

The high braking performance achieved through this conversion is due to the superior design of the calipers, the increased booster assistance, the overall brake balance and also the choice of disc pad compound. Any attempt to mix other components will upset the braking balance and performance. Anyone seriously considering upgrading their brakes is encouraged to come and drive my vehicle. The results are astonishing.

Cookey


2 x modified 276mm vented rotors @ 125-00 $250-00

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Personally Its a little over the top of the other kits I was looking at for doing the conversion, not enough to put it out of the picture tho.

I'd like to see one more thing prior to agreeing to purchase a kit (well 2)

1. The specification of the modifications to the rotors (final sizes + thicknesses for service inspection reasons)

2. lead time, anticipated delivery cost and delay

you should be able to get it engineered up as a drop in kit if you sell it with all the pieces including prefab lines for getting the MC in.

Hi Dave,

The rotors are a common size and are readily available in plain, slotted, drilled & slotted, etc. They are made in Aust by both RDA and DBA. I use the DBA as I believe them to be of a superior quality and finish.
Diameter 276mm
Thickness (new) 22mm
Thickness (min) 20mm
https://www.aulro.com/afvb/images/im...2013/02/11.jpg

The rotors are modified by increasing the centre bore to 100mm to fit over the rear of the hub.
They are also re-drilled to mount onto the rear face of the hub (5 bolts)
https://www.aulro.com/afvb/images/im...2014/10/42.jpg

I will have some kits ready by the 1st week in June. I would need to know what model they would be fitted to and if you were intending to exchange any items.

Shipping would depend on your destination, however, I imagine a courier service would give a quote. I often travel as far north as Tweed Heads and could take them that far without charge.

I have discussed the possibility of a "type approval" certification with the Engineer. Unfortunately the RMS (formerly RTA) are not processing any approvals of this type at this point in time. They are reviewing the guidlines and requirements at this stage and will not authorise any new approvals until the new regulations are finalised. (they have been doing this for several years)
In the meantime, each conversion will require it's own certification. (at least that is the case in NSW, I'm not sure of other States.)

Cookey

perfect,

Firm up the lead time for 2 lots to suit a series III front sals rear, drop me a PM when you're ready I have 2 sals and a couple of front series ends that I'll rat for parts for my kit and you can keep the extras to turn into parts for provision. Ball park me a weight and I'll do some legwork. (it'll probably be going onto a sII bulkhead)

I'll need you to do info push on this one for me as I've a lot on my plate atm but you've just nailed the sales on the first 2 kits you produce (exact specs to be outlined but at this stage Its looking like everything).

Guess that's got the brakes sorted out for all the extra power Fozzy's going to have now Dave.

was always going to happen, I was messing around with a couple of options including fabbing a set of mounts for some coiler housings with discs and retrofitting the 4.7's.

this'll be cheaper and maintain original parts in a few more areas. Its the savings Im making in those other areas that are bridging the gap for the cost of the disc conversion.

As I have a friendly engineer I'll look into getting him to sign off on the kit and make the inquiries about getting the kit license done for QLD. More than happy to help out by doing up kit install instructions if requried and IF I can get someone to take the photos.

Certainly looks like a good conversion. Just imagine all the extra spare time you are going to have now - no more adjusting snails.

never had to adjust the brakes, never used em, thats what the gearbox is there for.

Never worked out if I drive the box because its a better method of driving and it keeps the vehicle in the correct gear at the correct time or becuase Im lazy and dont like adjusting drum brakes.