Disc Brakes
 

Well, for those of you who know me I have a 99 GEM converted to GAS with a Yama G2/G9 Rear end with a 24 Honda, Well anyhow I just finished Fabbing one of the rear axles disc setup and hopefully will have the Caliper mounted in the next few days. So far heres the count (took lots of research for these parts)

2 1992 Geo Metro Front Discs (but on the back) 24.00 Bucks (napa)

2 1987 VW Jetta Rear calipers with new pads (with a cable E brake set up) 24.00 Bucks (pull a part)

8 5/8 to 10 MM spacers 1 inch long (used to center Disc, Wheel axle and wheelspacer) 6.00 Bucks

8 10x70 by 1.25 pitch bolts from home cheapo (16.00 bucks) Rip off

Having Rear discs while still remaining a E brake and having the back discs done four under 75 bucks (not counting the beer and research time)

PRICELESS


I figure the fronts to cost around the same or less, except they will be GEO metro as well with Geo calipers

Brian

Where's the pics?

There on there way! Hopefully withing the next day I will have them Posted.

Well here they are, hooked up the Ebrake cables and Drove it last night. Brakes work Great, Next is to convert the fronts to Discs (currently they are Hydrolic Drums on the front)

http://pic2.picturetrail.com/VOL976/.../231918634.jpg

http://pic2.picturetrail.com/VOL976/.../231918779.jpg

http://pic2.picturetrail.com/VOL976/.../231918719.jpg


Brian

Heres a few closer shots, Keep in mind even though its a GEM cart the Rear axle is a Yamaha G2/G9 setup, Any the dripping is because I just Bleed them.

http://pic2.picturetrail.com/VOL976/.../231921699.jpg

As you can See the Disc sits behing the axle

http://pic2.picturetrail.com/VOL976/.../231921684.jpg

The whole caliper and Mount Can be easiely removed and bolts on with very minor mods to another axle (Simply drilling the threads out)


Brian

Looks real good, once you get the front brakes on that thing it ought to be able to stop on a dime!

Nice job Brian, thanks for all the good info!!! 8)

Ok guys, heres some more pics to help the Yama owners

here you remove the axle and knock out all 4 studs and then I drilled the holes to be exactally 5/8 big

http://pic2.picturetrail.com/VOL976/.../232097586.jpg

Then you take spacers like these Which are 5/8 OD but only 10 MM ID

http://pic2.picturetrail.com/VOL976/.../232098070.jpg

Then you put them in the axletube, and in my case I used wheel spacers so I drilled the holes on the spacer to 5/8 as well so the spacers centered the wheel spacer


http://pic2.picturetrail.com/VOL976/.../232097626.jpg

Also you leave the spacers out exactally 1/4 behine the axle, This gives the Disc a flat surface to mate up to. And clean the backside if the axle and the spacers and weld the spacers to the axle on the backside so your spacers can not move.

http://pic2.picturetrail.com/VOL976/.../232097682.jpg

before reinstalling the axle you will have to drill out the threads at which hold the axle in and weld nuts on the inside so you can bolt it from the inside out. Because now with the disc in place you can not bolt up from where the drums used to be because of the disc being in the way.

http://pic2.picturetrail.com/VOL976/.../232097746.jpg

http://pic2.picturetrail.com/VOL976/.../232098120.jpg

And heres a shot of the Disc, as you can see its threaded for a 10mm 1.25 pitch thread, so you slip the disc up behind the axle and use 4 bolts to put it all back together then slide your axle back in and bolt together.

http://pic2.picturetrail.com/VOL976/.../232097660.jpg





Brian