Braking with Tradition

[Diana Alan]

What's a kit going to cost.

From AULRO http://www.aulro.com/afvb/technical-chatter/169784-series-disc-brake-conversion-i-did-my-way-post1865403.html#post1865403

After a great deal of thought and after liaison with my Accountant, Solicitor and Certifying Engineer, I have decided that this conversion will be offered for sale via 2 methods:

a) A complete drive-in / drive-out conversion, where all components are fitted by myself, in my workshop. This will include an Engineering Certificate for each individual vehicle. This will also include upgrading to Series 3 dual circuit pedal box, master cylinder, brake fail switch and the 8 inch dual diaphram booster, as well as fitting new rear wheel cylinders, regardless of model. SWB versions will also require the fitting of 11 inch rear brake assemblies. In other words, the brakes will be upgraded to exactly what is fitted to my series 3.

b) A complete pre-assembled kit of all components necessary to complete the conversion. Some items will be on an exchange basis. The exchanged items will have to be serviceable and of the correct type or a core charge will apply. The kit will include the front components pre-assembled, so that all that is required for fitting is to disconnect the front brake hoses, disconnect the tie rod ends, undo 6 bolts on either end of the axle housing, and bolt on the new assemblies. A pedal box will be included pre-fitted with the booster and master cylinder. The kit form will also be available as an outright purchase, without the need to exchange any items. I will be happy to supply a COPY of my Engineering Certificate to assist you with arranging your own certification.

Prices will vary somewhat depending on the model and if you have reclaimable items to exchange. A preliminary price guide appears below.

The high braking performance achieved through this conversion is due to the superior design of the calipers, the increased booster assistance, the overall brake balance and also the choice of disc pad compound. Any attempt to mix other components will upset the braking balance and performance. Anyone seriously considering upgrading their brakes is encouraged to come and drive my vehicle. The results are astonishing.

Cookey

Brake Conversion Pricing

Conversion parts
2    x  reconditioned 4 piston aluminium calipers       @  225-00    $450-00
2    x  modified 276mm vented rotors                     @  125-00    $250-00
1    x  premium grade disc pad set (Bendix Ultimate) @  160-00    $160-00
2    x  fabricated caliper mounting bracket              @  250-00    $500-00
2    x  modified swivel housings                                                        (exchange – core charge  $50 ea)                        @   60-00    $120-00
2    x  modified wheel hub                                                         (exchange – corecharge$50ea)                            @    60-00   $120-00 
2    x  modified brake drum spacers                                                  (exchange – core charge  $20 ea)                        @    25-00   $  50-00
1    x  modified pedal box (series 3 type)                                      (exchange – core charge  $100)                           @  100-00    $100-00
2    x  caliper steel brake pipes                             @   15-00    $  30-00
1    x  8” dual diaphram booster                            @  140-00    $140-00
2    x  master cylinder extended steel brake pipes    @    25-00    $  50-00
2    x  rear wheel cylinder                                    @    40-00    $  80-00
1    x  various sundries, lock tabs, nuts, bolts, etc.  @    50-00    $  50-00
2    x  railco bush to bearing conversion                 @    75-00    $150-00
Total                                                                            $ 2250-00           

Additional items if required
1    x  brake master cylinder (dual circuit)                             $  275-00
2    x  wheel bearing and seal kit                        @ $90-00    $  180-00
2    x  swivel ball seals                                     @ $35-00    $    70-00
2    x  lower swivel pin bearings                         @ $25-00    $    50-00
2    x  servicable stub axles                              @ $25-00    $    50-00
2    x  servicable swivel balls                             @ $95-00    $  190-00
2    x  servicable front axle shafts                      @ $95-00    $  190-00
2    x  serviceable rear brake drums                    @ $50-00    $  100-00
1    x  set rear brake shoes                                                $    85-00
1    x  dual circuit pressure differential valve & switch                                                    (series 3 type)     $  100-00
1    x  warning lamp modification  (if required)                                                                         $  100-00
                 
Fitting service
Series 2-2a                     $  825-00
Series 3  (single circuit)     $  715-00
Series 3  (dual circuit)       $  550-00
Stage 1 V8                      $  550-00 

Engineering Certificate                                                                                            $  660-00

Note:  all prices include GST where applicable

[juddy]

Thanks D

How long to fit.

By manufacturer

By buyer. Average

[Diana Alan]

Hi Juddy

Gary was saying that on a late SIII six cylinder it would only be a few hours, this is because he plans to have the assemblies pre assembled and exchange the ones that come off.  So its a matter of removing and replacing the rear brake cylinders, removing the six bolts on each axle housing, the track rod and one end of the drag link and the six bolts that hold the pedal box to the firewall.  Then swap over the 3 assemblies, swap the brake pipes bleed the brakes and do a test drive.

It may be as little as in by 8am and out by lunch.

Are you going to Corowa, Gary will have his SIII there for a test drive.

Diana

[juddy]

No will not be there his year, will he be at Sydney later in the year.

[Diana Alan]

Yes he will, or you could wait till Dave fits up the kit he's ordered and see what its like.

Are you thinking about it on the workshop?

[juddy]

I have been looking at a number of conversions yes, more so because I want the Workshop to be a better drive for the wife, and thus this may be of benefit.

However, I know of people who have very good standard brakes and say its not worth all the expense if you set up yours correctly.

I think I would need to drive one first to get a better feeling for it.

[Diana Alan]

I have been one of the people who support the drum brakes, however two things you can't get around is the that that the LR 109 system works poorly in reverse and the constant need to adjust the shoes.

Yes you can put the wider 3" shoes on the front, you can change the pedal box and fit a larger booster, even fit a dual circuit but you still wont get past the need to frequently adjust the brakes.

[juddy]

And I think that is for me the main reason from my point of view, of going for a system like this, no more messing about...

[303Gunner]

Diana, not particularly discussing this excellent conversion, but in general are vehicles with any Engineering Modification still eligible for NSW Historic Registration?

[Phoenix]

Diana isn't on her computer at the moment, but to answer your question.

Under NSW HCRS "Vehicles must be as close to or original condition as possible, with NO alterations except for safety features such as seat belts and turn indicators or period accessories and options, if desired." Disk brake conversions are a safety modification, there are other documents that back this up but won't go into it. Suffice to say that for modified vehicles, it is preferred the modification be done and engineered when on full rego and then transferred to historic.