C5 Rear Disc Brake conversion with E-brake in the works

[modular93fox]

Finally went to the bone yard and picked up a rear end. Even got lucky and found a 12 bolt rear end. What I will be working towards is 99-04 Corvette (C5) Rotors redrilled to the 5x5 pattern, C5 Calipers, C5 internal parking brake. The only modification that cant be done by the average joe would be having the axles machned down a bit. The OD of the axle flange is a hair over 6.5" and needs to be turned down a little, aswell as the center register on the axle. I will start to gather the parts here in the next week... waiting to see if I can win an ebay auction. If not, I will be getting the backing plate kits and calipers here in the next week.
The Dodge 13.8" disc conversion I did a while back still kicks butt!! But I still havent gotten the e-brake setup downyet. This is why I am starting the C5 converions.
Clint

[modular93fox]

Its like Christmas, but in August. FedEx droped off 1 of the 2 boxes. So far I have new C5 rear calipers and new C5 e-brake backing plates... woot woot... I'm hoping Thursday/Friday FedEx will drop off the rotors



clint

[choptop]

im watching closely

[modular93fox]

well FedEx didnt drop off the rotors Friday, shows on the truck for next business day..
On another note, Finally went from paper space in autocad to some 1/4 acrylic plastic... fine tuned the outline/shape of the bracket and voila:



and the back side showing the acrylic bracket - for race applications lol...


There will only be 3 bolts holding the backing plate to the adapter bracket. One on the top (thats the one you can see the hole is drilled through), and 2 at the bottom that go through the e-brake actuator.

I am lacking the rotors, so I do now know how far to space it just yet. The backing plate will be close to 5/8 away from the flange. The 4 axle flange holes in the backing plate adapter will be tapped. I am going to start on the caliper bracket now.. after a quick search, it the factory C-5  calipers sits 90* to the front. Setting it 90*to the rear would be as simple as using the opposite side brackets and calipers. This is how I set up the Dodge rear calipers on my truck now:



thoughts/opinions? Any case, the angle could be changed at any time with no problem.

clint

[Captkaos]

Set the caliper so the bleeder will be at the top.  I would put it at the same angle GM positioned it.

[modular93fox]

The factory C5 has them mounted facing towards the front of the car... but you can run it either way. If you want to have the calipers facing the back, like the fronts are, you would just use the left side brackets and calipers on the right side. Either way, the bleeder would be on top. I like them facing the rear, similar to the way the fronts are.

FedEx dropped off the rotors... after looking at it, the inside of the rotor has a machined face of about 6.25. Our axles are a tad over 6.5. While staring at the two, I was thinking instead of turning the entire axle down to fit the rotor,  just turn the outer edge (of the face), like a chamfer that fits within the stock rotor. Along with that turn the center register to fit the stock rotor. Sounds like it would be better so there would not be any extra costs each time the rotor needs replacing. I am going to the machine shop tomarrow to see what their advice is and costs involved. ... anywhoo, I loaded AutoCad Inventor 2010 so I wll post up a 3d of what I had in mind.
clint

edit:
heres a rendering of the axle mod that I was describing..



and a view looking down

[jaredts]

Cool.  I'm a big Autocad/Inventor buff.

[Captkaos]

I see what you are asking now.

If you want to sell these having a customer pull their axles to be machined will be and obstacle.

[modular93fox]

Yeah, I am finding out its a pain in the butt to find a machine shop that isnt buisy and will do it. My 1 hour lunch turned into 2. First machine shop's manual lathe was down, but he could do it on the CNC one for 180 for the pair.. passed on that offer. 2nd one didnt want to do it, 3rd was buisy and the 4th that was recommened by the 3rd was like another 20 minutes of freeway driving... I e-mailed moser axles to get an idea how much new ones would cost. Direct replacement axles are 225$ I am waiting on a reply with cost for axle depicted in the cad drawing.

clint

[modular93fox]

Well, in order to save me from driving from shop to shop to see if they can do the service I want, I decided to make some 3d cad drawings of what I wanted. The first option was to mod the rotor as shown here:

stock


modified


this way, the rotor will be ready to use on a bone stock c-10 axle with no machine work to the axle. Im waiting on a reply from the shop as I just sent it to them at 12am.. lol

[team39763]

You're pretty good with that CAD software.

What is the advantage of C5 stuff over the other disc setups that are more common?

[modular93fox]

You would be using new technology, matched caliper to rotor, vented rotors and e-brake. Some kits offered are impala rotors, and they are using different calipers such as LT1 calipers, d52 calipers.. mix and matched components. They all seem to work, but they are old technology. Heck McGaughys uses C5 front rotors and 80 model ebrake caliper that in other threads say that you must set parking brake each time to keep the caliepr working properly. But it also seems to work.

Plus once I iron the kinks out of fitting the rotor to the axle which I think I have... it could be upgraded to drilled/slotted rotors for C5/6 or the Z51 brake package or even the C6 Zo6 4 piston caliper.

I called Moser today about their stock replacment axles and they can machine them to fit the C5 rotor for no additional charge, just the standard 245.00.

Regular ac delco rotors I bought were around 45.00 (stock c5) , and the ones that are modified to fit other apps, which might include ours are 75.00. Thats 30 bucks for machining which isnt bad.

The idea is to use off the shelf parts for the brake kit so At any point you could replace them w/o waiting for the mail man. The measurements that were provided are close, close enought it might not fit. The option I am looking at is buying a set of new axles.
Unless you have a friend with a metal lathe, new axles or having yours turned is the option.

so far, 474.00 is new calipers, ebrake plate kit, and a pair of stock rotors.

needed:
Adapter brackets: estimated around 175.00
axles +225 (or find a machine shop that will turn yours)
brake pads +40.00
E-brake cables + estimated around 60.00

[modular93fox]

Well before I placed the order with Moser, I called a place that I had done business with a few years ago. I had a ford 9" built and was like lemmi give em a call... turns out he can do it... lol they guy gave a rough quote of 75 for both.. now I can work with that. Going there tormarrow morning and he said I could wait on it... By this weekend, I should have everything besides the cables mocked up.

[beastie_3]

[modular93fox]

Got the stock 12-bolt axles turned down just like I had drawn up in AutoCad.... awesome, fits just like I had planned for. Now if I could only do something about getting the weekend to come any faster.. lol
clint