I want to make a set of disc brake brackets and master cylinder mount for a Corvair Greenbrier, and I'm looking for experienced advice. What would be a good way to mock up some brackets? I'm thinking of testing my design by cutting out the pattern in A656/A656M steel with a plasma cutter, then drilling the holes for the bolts. If I need to weld two pieces together, I can do that in the shop too. After I'd settled on the design, I could have the final version CNC laser-cut, also from A656/A656M steel plate. What thickness steel should I use? How should I choose a caliper and rotor? My first thought was to look at Corvette parts, because they're relatively ubiquitous and inexpensive, and they'd keep the car Chevy. I might be able to fit them inside the stock 14" Chevrolet steel wheel. Another way to go would be Wilwood. One of Wilwood's remote reservoir masters looks like a good choice. I could make a bracket to bolt it up to the Greenbrier's body using the same methods I'm using to make the brackets. Thanks in advance.
A lot of modern cars have rotors that fit over separate hubs. Ideally you can find a set of rotors that will fit over your existing drum brake hubs. Finding rotors that will fit into 14" wheels mill add to your challenge. The next option is to find rotors with hubs that will fit on your spindles, fortunately, there are a lot of bearing choices available, but seals might be a different story. spacer and sealing surface collars can be machined to solve the seal issue, but those usually result in spacing the rotor closer to the end of the spindle, which may or may not work. I think I would look into what the newer Camaro's are using, since the bolt pattern probably matches your current bolt pattern. Once the rotor issue has been addressed, the caliper mounting bracket has to attach to the spindle mounting bolts. it needs to be attached to at least 2 spindle bolts, but 3 would be better. The rotor you use will dictate the size and shape of the caliper mounting bracket. Generally, most caliper mounting brackets I've seen are 3/8" thick and use the GM caliper that mounts on the two threaded bolts. Those mounting bolts need to be vary close to the outer surface of the rotor for wheel clearance, and be sure to accommodate clearance for a brake caliper hose. In making caliper brackets, I would probably start with heavy cardboard to get a rough design. I would refine that rough design with a piece of plywood, and then transfer that to your steel. If done correctly, the brackets should be identical or mirror images of each other. It might be worth your while to look at pictures of some of the aftermarket kits available if you need clarification. Its important to size the master cylinder to the other brake components your planning on using, a larger diameter plunger on the master will result in more fluid delivery, but will also take more pedal effort to depress. A smaller diameter plunger will be easier yo depress, but may not deliver enough fluid for the system. There are lots of options available, and more then one might easily adapt to your car. Gene
I did it on my NAPCO, If I had to do it over again I would follow Gene;s advice, cardboard first and then wood. I went from cardboard to metal and had to re-do them four times. That was just the mounting brackets. Luckily I was able to use caliper brackets from a 2000 Silverado and just modify them a bit. You may be better at this than I, but Gene's advice would, in the long run, have saved me time. don
I would think there are brackets already made to to that job. Either factory or aftermarket. I never looked, just guessing. Didn't some Corvairs have disc brakes?
I understand wanting to make your own stuff. I know all to well about needing to make my own stuff. But,,, http://www.corvairunderground.com/govair/page6.htm http://www.corvair.com/user-cgi/catalog.cgi?function=goto&catalog=MAIN§ion=MAIN&page=150A http://www.californiacorvairparts.com/category.php?id_category=17
I have made a few sets of caliper brackets for disc brake conversions and I have first made a cardboard pattern and then a sample from 3/8" plexiglass. The plexiglass is easily 'machined', permits holding tight dimensions and being transparent has advantages when mocking up. Should you need a multi-piece bracket, the plexiglass can be bonded with a suitable adhesive. Ray
Have you checked Scare Bird Enterprises? 'Bout 100.00 bucks and a parts list any wholesaler can fill for cheap. Hardly worth making your own for that.
Scare bird has the brackets for about $100 and they adapt low cost S10 4x4 rotor and caliper. Was a super way for me to go the last time I changed to disc from drum. I had engineered them before, but took a long time and cost just as much in the long run. S10
I can tell you corvette calipers won't fit inside a 14" wheel. They just barely fit inside a 15" wheel. So unless you plan on going to a larger wheel, corvette stuff is out of the question. If you decide to use a larger wheel and go down this road....don't consider anything but a SS sleeved and O-ringed caliper. I did this conversion on my 66 impala.
If you want to pursue making your own, use the drum hubs for your wheel bearing, machine the outer edge if necessary to fit into a rotor. 68-81 vette rotors are an option as well as 78-80 whatever montecarlo. The stock car guys calls these metric chassis and are the basis for a lot of claimer classes. Speedway has all of these parts cheap. 80's impala are also a good source. See if you local auto store will let you measure the offset depth of the rotor, back "inside" of rotor, wheel mounting surface to rotor surface. Calipers, consider the same cars as well as s10, silverado etc, common easy to find parts. Clamp the caliper on the rotor, You want to get your rotor offset and caliper mounting surface aligned with you spindle mounting surface to enable a single plate with no goofy offsets. To get started you can straight edge your spindle mounting surface and hub surface to get an approx total offset then go shopping. Keep in mind your master cylinder needs to match bore diameter for the brake system you have planned. This site covers how to do this swap on first gen camaro before readily available kits were on the market, http://www.pozziracing.com/cheap_big_brakes.htm same idea applies to what you are trying.
You can find rotor specifications on the website of the major auto parts companies. Saves a lot of effort for all parties and it doesn't depend on the store's inventory Ray
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