Drum To Disc Conversion Queries

[rikky 37]

i'm converting my 1.6 drum rear beam to discs. in short, if anyone can guide / confirm:

1) i'll need the discs, calipers, handbrake cables, stub axles and the hub assemblies from the 1.9
2) the bearings within the hub are infact already pressed into them when you buy it, thus not 'servicable', and the part number for the bearings (370152) is the full assembly ready to bolt onto the stub axle?
3) is it worth just buying new stub axles from like Neat on eBay? think they're about £60 a pair. worried about using 2nd hand stub axles incase of damage from the bearings / races etc upon removal of them
4) removal - is it just a case of tapping the old stub axle out from the outside towards the inside? and then the hub assembly / bearings would all fall off? or can you pull it from the otherside? i'm not in posession of a puller, would rather tap it out either carefully or with a nut on the end or similar

also, i'm going to keep my 1.6 angled compensator on the inner NSF inner wing and split it to each caliper via a T piece at the rear end. i guess this will be ok to do, but it might cause earlier brake lockup than on the 1.6 drums?

 

i'll be whipping the beam off at weekend and starting to dismantle it so...

anything else to add / any comments etc?

[Tom Fenton 1,541]

As well as the parts you list, you also need the caliper mount brackets from a 1.9.

 

Personally I would not just buy new stub axles for the sake of it, I have re used them many many times with no issue.

 

To remove them yes they need to move towards the "inside" but forget tapping, they need a fair wallop to get them moving, I use a substantial soft alloy drift and a big hammer.

 

Don't forget you will also need to make brake lines from the flexis between body and beam, to the calipers.

 

Also you don't really need to remove the beam to do the work, perfectly feasible to do it with the beam still on the car.

[Anthony 1,002]

also, i'm going to keep my 1.6 angled compensator on the inner NSF inner wing and split it to each caliper via a T piece at the rear end. i guess this will be ok to do, but it might cause earlier brake lockup than on the 1.6 drums?

Using the 1.6 compensator and brake pipe layout is fine, and is my prefered way of doing it as opposed to changing it to a "proper" 1.9 setup.

 

Basically, all you need to change is the solid brake pipes on the trailing arms as Tom mentioned above, and the rest of the system from the beam flexis backwards can stay as is (although if you've not done them already, you'd be well advised to check the condition of the solid pipes under the car - particularly above the fuel tank - as they'll be in very poor condition if original).

 

This is how my current 205 is run (originally a 1.6) and how my last one was done also, between the two of them covering 70k+ miles over several years and in all seasons and conditions. Brake balance with 1.9 calipers on the front seems very good, with a decent amount of rear brake effort but never prematurely locking a wheel.

[rikky 37]

cheers for the replies, it's a complete rebuild so no lines or anything currently in and will all be brand new and repiped anyway

 

the beam will be off the car anyway to do the work

 

edit> sorry yes i knew i needed the caliper mount brackets. i'm not going to bother with disc protectors though

Edited December 13, 2012 by rikky

[rikky 37]

anthony: sorry forgot to add i've got gti6 brakes and mc / reservoir on the front anyway, not that it really matters

 

i'll be on the lookout for some of the bits soon, i've asked a couple of people already so waiting on replies, but if anyone's got some calipers / caliper brackets / stub axles then feel free to let me know and i'll bear you in mind

Edited December 13, 2012 by rikky

[Anthony 1,002]

I've got the whole lot if you need it - pair of calipers and all the bits to go from a drum to disk rear arm. Say £80 for everything?

[rikky 37]

well, i'm waiting for kenny to get back to me about a scrap beam he's got off a 1.9, so i'll be in touch if it doesn't come of anything

Edited December 13, 2012 by rikky

[leemundo 3]

Hi Anthony. Just wondering if you still have the brake set just Im picking up a 205 rallye Saturday and will want to do the conversion. It does come with a pile of goodies not sure if it has the parts required to do a rear brake conversion will find out Saturday

[ORB 227 1 Cars]

I'm not quite sure I understand the whole point on converting to 1.9 rear brakes?

 

It's not really an upgrade and its a load of hassle!

[rikky 37]

.. but easier from a servicing point of view

[pug_ham 244 3 Cars]

.. but easier from a servicing point of view

 

But generally worse for the handbrake point of view & its not like rear brakes really need much servicing.

 

Also, wheel cylinders are far cheaper & easier to replace than calipers if you get a seized bleed nipple.

 

g

[p1234 22 2 Cars]

I was all geared up to change to discs on the rear but after reading a few threads I decided to stick with drums, fitted new handbrake cables and have to say its spot on,

 

Made a few quid selling the disc beam I had too which is always a bonus.

[Anthony 1,002]

Six of one and half a dozen of the other really.

 

Losing the poxy self-adjusters is argueably almost worth a rear disk swap alone...

 

Hi Anthony. Just wondering if you still have the brake set just Im picking up a 205 rallye Saturday and will want to do the conversion. It does come with a pile of goodies not sure if it has the parts required to do a rear brake conversion will find out Saturday

Yes I've still got everything needed if required