Rear Disk Conversion for the Lemon

De-Ranged · Post by **De-Ranged** » Sun Apr 02, 2006 12:34 am

Had a few people ask about this one so I thought I'd show this in a bit of detail....

My Conversion is based round a set of Nissan Maxima 3L rear calipurs, I chose these becouse they have a cable attatchment for the handbrake, they have a minimal profile on the outside of the disk and

they cost me $40 for both

Right first off I stripped the old brakes

I cut the backing plate off to make it easyer to deal to the studs (which I'm replacing) and hell who wants to buy drums??

With this gone you can smash the studs out, as you take em out replace them with bolts, you'll find it easyer this way than trying to knock them out of the bearing carrier later
With them gone you can take the axle out of the axle tube, could be a good time to replace the bearings and seals if they need it
I did this with mine, but isn't necicery as most machine shops should be able to machine the hub flang down without removing the bearing

If your going with early hilux solid disks you'll need to take the hub down to the same size as the deflector plate bolted to the back of the hub other options you could look at include Pajero - Patrol disks as they have a deeper offset from the hub
Here's a shot of the hub flange showing how much came off

There is one downside with my disk calipurs they run a slightly narrower disk than the solid lux one so I took 2mm off to fit them while I was at it I groved them to help sustained braking and clearing mud :twisted:

and cose it looks good :lol:

Thats enough for now, its now tomorrow I'll throw some more up later

Cheers Reece

Rangielux · Post by **Rangielux** » Sun Apr 02, 2006 8:59 am

Good thread topic, I've got 3 rear disc conversions lined up

so the info is very handy. Caliper choice and caliper mounts is the main issue with most conversions I think, there is still a number of different variants that have been tried but most seem to have a downfall somewhere

(weakness, interference on rims) I'm wondering what the mint conversion is?

Could you have used some semi worn pads in the maxima calipers to overcome the disc thickness problem? (the discs do look cool tho)

krawlr · Post by **krawlr** » Sun Apr 02, 2006 9:22 am

just spin a few thou of the disc ,easy as man :wink:

De-Ranged · Post by **De-Ranged** » Sun Apr 02, 2006 9:26 am

I've got a lathe so its no problem to skim them down, the only safety issue is that you don't skim them to the point on worn pads the calipur piston can leave the housing, pay to take the measurements with you when you go for cert :wink:

easyer you make it for them the less they look

downfall somewhere (weakness, interference on rims)

Unless your willing to pay through the nose for EA falcon rear disk units or williwood's what you get with the maxima calipur (piston size & pad size) is pretty much the same with all the other easily available jap disks, the bonus I found and why I'm running them is the calipur dosn't interfear with the rim as much as someothers, if you use the others just change over to the Pajero or Patrol disks as they have more offset :wink:

As for the mount, to avoid issues with welding strength I'm doing a bolt on. I'm replacing the studs with grade 12 cap screws and using a 12mm profile plate that bolts to 3 of the studs :twisted:

it'll be strong enough!

More soon

Cheers Reece

Rangielux · Post by **Rangielux** » Sun Apr 02, 2006 6:41 pm

Looking forward to the photos. If you were to use a disc with more offset would you still be able to use a bracket off the axle housing bolts for the caliper mount?

Handbrake efficiency is an issue too. It seems to be hard to find a caliper with a good H/brake set up. Will be interesting to see what the maxima ones are like. I'm not worried about the certifier these are all bush trucks, or for the PC people "club trucks"or "club OHV" :wink:

SupraSurf · Post by **SupraSurf** » Sun Apr 02, 2006 9:02 pm

I've got std lux solid rotors on the back with a set of Mitsi Gallant rear calipers.

Pretty easy mount from the 4 axle flange bolts and the caliper fits over the disk

Not a very good pic but I can't find any recent ones

De-Ranged · Post by **De-Ranged** » Sun Apr 02, 2006 9:30 pm

There ya go another option, looked at that

but the cheaper set won out :lol:

when I measured the galant disk it wasn't as thick as the LN65 disk do new pads fit in there Mike??

Anyway heres a pic of the calipurs note the hand brake attatchment is on an angle I'm gona turn that a bit

Heres a shot showing clearance, just ignore the spacer on the outside fitted it to hold the disk in place

so in truth I have no clearance issues at all

I've delt with the clearance issue becouse I've a couple of mates who arn't running spacers and want to do the conversian

If you were to use a disc with more offset would you still be able to use a bracket off the axle housing bolts for the caliper mount?

No problems I'm going off the wheel side of the bearing carrier bolts if you move to the inside you'd be 15-20mm deeper

Should have some more progress tomorrow

Cheers Reece

SupraLux · Post by **SupraLux** » Sun Apr 02, 2006 10:27 pm

I have the same setup as Mike running on my MU and it works bloody well... apart from that handbrake issue.

I've got Hilux solids, machined to fit the hub (hub flange machined as well) and Galant calipers mounted on 10mm plate brackets, with a 15mm spacer between the caliper and the plate to get the correct alignment onto the disc. Oh, and I put brand new pads in mine and they fit fine... tight squeeze, but they do fit fine.

The handbrake sucks ass. I've got the standard MU handbrake cables modified with the galant 'knobby things' on the end of the cable and custom brackets welded to the axle tube to mount them (photos to follow when I get time/remember) and with both hands pulling up the handbrake cable I can still (just) push the vehicle and break traction.

I'm going to give the Isuzu ones a go since I have a set here... but I believe all mechanical handbrake options like that are rubbish which is why they have all gone to drum-inside-disk.

Steve

Rangielux · Post by **Rangielux** » Mon Apr 03, 2006 8:49 am

hmmm, the handbrake issue. It's the handbrake thats half the reason for us to do the conversion on the lux's.

If Toyota was being truthfull in the early ads for Hilux then it would show the Hilux f ing off down the hill with Scotty in it screaming while Crumpys standing outside rolling a smoke :shock:

(mud=no handbrake)

I did glimpse that "tin foil" in 4x4 Action had a poor H/brake with the E33 Galant cals. Will be interesting how D-Rs H/B works out?

I've always thought that the Sub Leones had a efficient H/B set up(the ones that were on the front), but its been said that they're a bit weak?

Great info coming from this thread

SupraLux · Post by **SupraLux** » Mon Apr 03, 2006 1:05 pm

For Hiluxes you can just mount a t/c output flange disk and go-cart mechnical caliper (something like the allpro offroad one) - theres plenty of bolts on the back of the t/c to mount it - not an option on the one-piece casting of the MU box.

http://www.allprooffroad.com/index.php?option=content&task=view&id=33

Then you have unbeatable holding power on the handbrake (just don't pull it on while moving - aparently makes a very nice spiral pattern on your driveshaft

), and you can use any old caliper that suits.

Steve

De-Ranged · Post by **De-Ranged** » Tue Apr 04, 2006 8:55 pm

Its his fault (pointing at Steve)

I've decided to change things a bit :roll:

liked Steves link so much I've decided to give it my spin :twisted:

I'm going to put a two pot caliper on a small disk and link it to a clutch master (just got to find one that pumps the right amount :roll:

theres always a hitch :lol:

)
Oh and as for my back brakes :twisted:

run solid disk hilux (LN65) disks and calipers

As for the Maxima caliper conversion, I will be going ahead with this on a mates surf ..... but its on hold till he can get the coin for parts... got one more post to with the mounting plate then the rest will have to wait till he's ready

Sorry

Cheers Reece

ps anybody got a set of early lux front calipers :wink:

krawlr · Post by **krawlr** » Wed Apr 05, 2006 7:07 am

D-R bugger just through some out :oops:

getting sick of crap everywhere and i offered them to mates and no joy there :cry:

i use the ifs calipers on the beam axle they work awesome :!:

Jafa · Post by **Jafa** » Wed Apr 05, 2006 8:20 am

Yer I like the TF case handbrake idea, I decided on that when I first saw the Allpoo one, I'm gonna use either a go-kart hydralic caliper or one of those cool little Willwood spot calipers, with a hydraulic handbrake setup like I had in my rally car. The only problem is getting it cert'd, has to be exempted like a rally car, so log book, car cliub, 3 events a year blah blah blah, all the same crap for a MANZ cage and belts etc

SupraLux · Post by **SupraLux** » Wed Apr 05, 2006 11:08 am

If you just use a mechanical disc caliper (some trailer tyes or some go-cart types - I have one here, I'll look for part number markings) then you can use the t/c mounted one without the exemption... just needs to be cert'd as a braking mod.

Steve

Jafa · Post by **Jafa** » Wed Apr 05, 2006 11:43 am

yer but i'm getting the belts,cage and plastic windows exempted so 1 more on the pile wont hurt :shock:

Rangielux · Post by **Rangielux** » Wed Apr 05, 2006 7:58 pm

Saw a trojan trailer type mechanical disc caliper the other day when wandering at supercheap and played with it and scratched my head wondering where that would fit best :scratch:
$95 approx and had quite a decent lenght lever on it too.

De-Ranged · Post by **De-Ranged** » Thu Apr 06, 2006 9:51 am

:scratch: at that price its about what I'm gona be paying for clutch master cylinder and caliper without

new pads !! Wonder how much power they have

As for the cert stuff, I was looking at same deal as jaffa as my rollcage exteral/internal will be a bit hard to push through as a roof rack :lol:

my certifier races so he knows what its there for :roll:

Cheers Reece

Rangielux · Post by **Rangielux** » Sun May 21, 2006 9:22 pm

All credit to DR :wink:

I ran with his idea to do the Maxima caliper conversion.

went together really well and did 10 km's down the road to bed them in a bit and check the h/brake & seems pretty good . Sending it up to a farm for testing. Repeat all credit to DR's idea

Rangielux · Post by **Rangielux** » Sun May 21, 2006 9:32 pm

Oh for those eagle eyed guys looking at the PS spring on the R.H. side.
This surf is LH drive

(ex Iran - don't ask its a long story)

De-Ranged · Post by **De-Ranged** » Sun May 21, 2006 10:12 pm

Sweet!!
Noticed you modified the handbrake arm, nice
Still haven't finished the one I was working on, sold it to a mate whole axle with all the fruity bits... when I've finished it

Been working on a meaty'er option :twisted:

Wide body'd Surf rear axle with Pajero rear disks and early 4pot hilux solid disk calipers :wink:

and it all fits without spacers... well it will when I finish the mounting tab

she's gona be trick!!
Oh and the handbrake thats now on a cable disk on the back of the trans

Cheers Reece

Rangielux · Post by **Rangielux** » Mon May 22, 2006 8:50 am

De-Ranged wrote::D Sweet!!
Noticed you modified the handbrake arm, nice

Yeah it was a real simple coversion and for the h/brake arm I just cut a length of 25x5 flat, slotted it thru the original lever and welded it in place and drilled a hole in it.
I had the discs already $40 cals $40 mount brackets and 6 bolts = rear discs for under a hundy

hosehustler · Post by **hosehustler** » Mon May 22, 2006 3:00 pm

nice job

did you buy the calliper brackets or make them

doing the same mod to my beastie soon, sourced a IFS rear axle housing (cheers Matt), I have a set of SSS Bluebird callipers, look pretty similar, just gotta source somebody to turn hubs down :roll:

De-Ranged · Post by **De-Ranged** » Mon May 22, 2006 5:51 pm

No problems, just drop them in here after work and I'll nock them up for ya .....

oh yea thats right you don't live up here

With the surf axles when you do the axle shafts you'll also have to do the inside hole on the solid disk as the brake locating flang on the axles is bigger

If your interested I've got a set of new solid disks that have been machined out to fit and groved

decided not to use them when I got hold of a set of early 4pot hilux calipers :twisted:

Cheers Reece

Rangielux · Post by **Rangielux** » Mon May 22, 2006 7:18 pm

Got the brackets profile cut for the maxima ones. Got three done at once for 3 lux's I've got to do. PM your postal address if your keen and I'll send a photo copy of the drawing.

If you own a grinder and axle stands turn down the hubs yourself - I did. If you're carefull It can be done

SupraSurf · Post by **SupraSurf** » Mon May 22, 2006 11:06 pm

Leithfield · Post by **Leithfield** » Tue May 23, 2006 7:12 am

Am using the Sky Manufacturing T.C. mounted emergency brake (same as All Pro but more robust) on my Surf - works a treat. Very basic design. Cheapest option for this now is to import calliper & rotor here http://www.allprooffroad.com/index.php? ... view&id=33
(they will post via USPS surface mail - real cheap, but slow)
& fab your own mounting bracket.

hosehustler · Post by **hosehustler** » Tue May 23, 2006 8:19 am

SupraSurf wrote:
I got some brackets for the bluebird calipers if you need..

If you want to turn down the axles get a big grinder
Yours are easy, stick it up on axle stands take off both wheels ( remove all the old drum junk first ) stick the axles back in and get some one to turn the opposite axle and get the grinder into you side and it makes a nice job

cheers Mike, I'll give you a call

Rangielux · Post by **Rangielux** » Tue May 23, 2006 8:26 am

SupraSurf wrote:If you want to turn down the axles get a big grinder
Yours are easy, stick it up on axle stands take off both wheels ( remove all the old drum junk first ) stick the axles back in and get some one to turn the opposite axle and get the grinder into you side and it makes a nice job

and it's easier if your rear is welded like mine, front hubs out 2nd low and away you go. watch out for excess heat build up and it'll work out fine.

Kiwi ingenuity at it's best.

DJ · Post by DJ » Tue May 23, 2006 11:00 pm

Hi Rangilux
looks good but what did you use for the brake master cylinder as orginal is designed for disc front /drum rear ?

This surf is LH drive (ex Iran - don't ask its a long story

hey I seen that at Pureora ( north/) awhile back ....different... Scottie and I there with the supra hiluxs

Rangielux · Post by **Rangielux** » Wed May 24, 2006 8:18 am

Yeah DJ the sound of those singing six's still ring in my ear

Will be bringing the V8 lux and two other lux's over to Scotts rere do in July

- might see you there :?:

Still on the standard m/cyl. at the mo minus the proportioning valve of course. Just testing it and seeing what happens - seems to be going ok so far, no binding or lock ups etc (only done 30ks tho). Should be better than what was there before - no brakes at all ! Will change it if problems arise. I dont know what m/cyl. other guys have used - prado, 80 cruiser maybe? Some out there will know