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

whichitygrub · 30th October 2014, 01:02 PM

Originally Posted by cookey

I have retained the original rear brake shoes and drums, however I have reduced the diameter of the rear wheel cylinders. Reason being, the front calipers have no self-energising ability and therefore require an increased hydraulic pressure to obtain the desired increased clamping force. When this increased pressure is applied to the rear brakes, there would be a tendency for the rear wheels to prematurely lock. By fitting cylinders of a smaller diameter, the force applying the rear shoes is reduced (pressure x area of pistons). The cylinder diameter must be reduced by the correct amount to have maximum rear wheel braking without lock up.

The caliper mounting brackets are a one piece design machined from a block of mild steel, which starts out at 32mm thickness.

This is machined in such a way as to provide the correct offset to mount the caliper centrally over the new rotor.

The finished mounting bracket looks like this.

The bracket is drilled on a jig to match the stub axle bolt pattern and drilled and tapped to mount the caliper.
The back of the hub is machined to take the rotor, which is mounted by 5 high tensile bolts.

The rotors are common and readily available, however some machining is required.
The 4 piston alloy calipers are superior in design to Land Rover/Range Rover types and are readily available, however some machining is required.
The hubs are standard Series 3 or Stage 1, however some machining is required.
To maintain the original wheel track and to provide clearance for the calipers, the centre of an original front brake drum is machined out and attached using the original retaining screws.

The original front brake hoses are retained.
The original brake pedal box is modified to accept a dual diaphram booster and new brake pipes made up to suit.

Cookey

Hi Cookey great setup am thinking of going the same way with my 63 2a and would like to know what roters and calipers you used thanks.
cheers William.

**Lotz-A-Landies** · 31st October 2014, 12:51 AM

That's Mk1 the current Mk2 design includes different brackets, different rotors and different callipers.

I don't know about you, but if I'd spent weeks machining, prototypes, then discarding them to improve alignment or clearance on the next prototype by less than a mm, spending hours and hours searching catalogues and buying samples only to find they won't fit or have other problems I wouldn't be giving away all my accumulated knowledge for free.

Gary has a stack of blanks for Mk1 brackets that you could use as legs for a coffee table with chairs made out of the Mk1 rotors both of which he won't be using.

However Gary is too polite to say what I have just said.

**sclarke** · 1st November 2014, 02:20 PM

Awesome kit

**Davo** · 1st November 2014, 02:59 PM

Originally Posted by Lotz-A-Landies

That's Mk1 the current Mk2 design includes different brackets, different rotors and different callipers.

I don't know about you, but if I'd spent weeks machining, prototypes, then discarding them to improve alignment or clearance on the next prototype by less than a mm, spending hours and hours searching catalogues and buying samples only to find they won't fit or have other problems I wouldn't be giving away all my accumulated knowledge for free.

Gary has a stack of blanks for Mk1 brackets that you could use as legs for a coffee table with chairs made out of the Mk1 rotors both of which he won't be using.

However Gary is too polite to say what I have just said.

I'm glad Gary is polite, because you're not. That was very rude.

Maybe he didn't think about all the work put into this. Maybe he's never done something like this and doesn't know how difficult it is to make all the parts work together as those of us who have done things like this do know through our experience. That was the guy's first post. Nice welcome to a new member.

This is why I don't bother with this forum much anymore. Maybe the next time someone offends you, you can have a gentle word with them instead of the written equivalent of dropping a hand grenade down the front of their trousers while questioning their parental heritage.

Back on topic: excellent work and l'm looking forward to how it all turns out.

**Lotz-A-Landies** · 25th November 2014, 10:24 PM

Just an update, Gary has 10 axle pairs of Mk2 calliper brackets in his workshop. He has machined a pair of hubs and rotors for the first front axle prototype testing which may be fitted next weekend.

That will then undergo engineer testing and certification.

He will subsequently fit up a set of rear disks and undergo a second engineer certification.

If all goes well front axle sets will probably be available for sale in the new year and 4 wheel sets shortly after that.

**Homestar** · 26th November 2014, 05:08 AM

Great news.

Don't let him forget to put my name on one set. If a deposit is required, that's no dramas.

**dickyjoe** · 15th April 2015, 08:38 PM

Just read through this thread with great interest. I went down the route of fitting disco brakes and calipers to my Series 2a. I like this design for its bolt on approach!

Well done.

**Homestar** · 15th April 2015, 08:49 PM

They are really well designed. I've just bought a set, and I've driven Cookeys series 3 with them fitted - it's a very nice drive, and stops like a car.

**Blknight.aus** · 15th April 2015, 09:53 PM

Originally Posted by travr

Gday Guys
my name is travis and i currently one of the RAEMUS Rover team members. through out this year we have found the more the car progresses the harder it becomes to stop. so as a team we are looking at options at a disc brake conversion to the vehicle. blknight did you end up getting this kit ? i would be very interested in what you think. and does anyone have contact details for cookey? i have sent him a PM so hopefully he will get back to me. If any one here is interested we now have a Facebook page for RAEMUS rover feel free to look us up. I will also look to update the RAEMUS Rover thread on your site when i get a chance.
cheers travis

Yes I've got the kit, no I havent fitted it, although it and the vehicle they are going to go onto was one of the few things I managed to keep through the divorce.

having to do the same engine 3 times in the EX's disco along with the gearbox didnt help the budget for fixing the vehicle the brakes were going into, when I've dug myself out of this hole and get the vehicle sorted I'll let you know

**Homestar** · 29th September 2016, 12:01 PM

Just thought I'd relate my tale of fitting of of these kits - most here know that I'm rebuilding a series III and am using a set of Cookies disk brakes on it. I've now fitted them and although I can't drive the car yet, the entire brake system is finished ready to go basically.

I bought a full front conversion kit which not only included the disk brake bits, but also a dual diagram booster, new master cylinder and new rear wheel cylinders (that make the front to Rea bias correct). The booster and master cylinder were already mounted to a pedal assembly (which is a change over unit when you buy this bit) so all you do is drop it in the footwell and bot it in - done.

The disk brakes were truly a bolt on proposition, and all very easy to do. The kit even comes with 2 new swivel housing filler plugs (the 1/2" BSP ones) that fit flush in the housing as the original sticky outy ones will foul the calipers, so everything's been thought of.

I would highly recommend this kit to anyone who is thinking of going down this path. I've driven Cookies Series III with this kit fitted and it really stops like a car, and dead straight.

Really pretty to look at too - here's a pic of one side all fitted.

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

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