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

[modular93fox]

Made a little more progress today..



The caliper can be mounted to the front as shown, or to the rear

I need to cut some more acrylic brackets to space it out better, but it looks like the thicker bracket will be either 5/8 or 3/4.... 3/4 might be a hair too thick but I need to take a better measurement. This thick bracket will space the ebrake backing plate inside the rotor hat.
The caliper adapter bracket will be 3/8... plenty beefy

here are some renderings with the updated design of the ebrake spacer



and it assembled on the "axle"



maybe one more day of mock up and I will order the first set of lazer cut brackets.
clint

[modular93fox]

sent the files over to the cutter today... hopefully they can cut them this week and ship on Friday...
clint

[bake74]

    That's a lot of work, can't wait till it done and see the finished product....Tom

[jaredts]

So drilling the different bolt pattern in the rotors is the only mod for replacement parts?  That's not bad.  Did you check on waterjet instead of laser cutting--I think its a little cheaper, maybe not.  What material are you using for your brackets?  4140 pre hard or something?  Are you new to Inventor--I've been using it for a couple years and so far its been good to me.

[78 Chevyrado]

It coming right along ain't it?  I'm waiting with my popcorn to see how they look and it all comes together!  Nice looking work man.

[modular93fox]

So drilling the different bolt pattern in the rotors is the only mod for replacement parts? 

Thats the only mod to the rotor. The axle needs to be turned down to fit the rotor, or you can purchase new axles from moser and they will turn them down to spec for you... depends if your axles are not worn out (the 12 bolt ones I had turned down are worn out )

As far as the brackets, I was waiting for about a week to get a quote and hadnt heard anything form him, this was going to be CNC machined part... Still waiting, but went ahead and changed the bracekts so it can be cut on 3/8 steel plate + spacer to space the ebrake assembly to position. Same design, just makes the "kit" a lot cheaper.... probally saves me upwards of 150 per set... CNC stuff gets cheaper if you do large quantities.. and right now Im doing small quantities ... around 10 at a time.

Tonight I am going to order some brake pads and e-brake cables from rock auto... they have a special on the brake pads.... 15 mail in rebate.. 48.00 from oreilly, 35 from RA, plus 15$ rebate yeah

Yeah, Ive been using Inventor 2010 for about 9 months (fun only / self taught) and Autocad 2009 for 2d stuff for about 1 1/2 year...

clint

[modular93fox]

heres what I will recieve from the cutter:



clint

[the dan]

Are you going to have the brackets lasered? if so i can get you a quote from my shop

[modular93fox]

either lazer or waterjet.. Ive gotten quotes from all over the country... all within reason unless you want just one side.... I am waiting for my last bid to come in, and then I will make my decision. I found a place about 20 miles from me that can do one side or set at a fair price. This is also the first place that said waterjet is a cheaper way... i guess setting up a lazer is more? he said they have a minimum charge of 250 for the lazer and 100 for the waterjet..

clint

[modular93fox]

wow, finaly got the call .. well finally checked my voice mail. stupid jailbroken iPhone.. phone no longer displayes the visual voice mail... didnt know my brackets were ready... picking them up at lunch time, just in time for the weekend
clint

[modular93fox]

ha, turns out they have been done since 10.18 .. whoops



I will do some test fitting tomarrow afternoon.. gotta go into work and finish up a car. Need to finish adjusting valves and replace a manual transmission on a 08 z3 Mcoupe

clint

[modular93fox]

the measurements were spot on, here are some (iPhone) photo's:




Its centered, poor camera angle ..doh


Mostlikely you cant see it but the 1/2 bolts that go from the outside of the main bracket to the caliper adapter head had to be ground down to the thickness of the 3/8's head. When the 1/2 bolts were in place, you coldnt slide the axle in far enough to insert the c-clip. Thus requiring the grind down the head of the 1/2 bolt. Only other way w/o grinding down the head would be to use 5/16" thick steel as the main bracket, probally plenty good and strong but 3/8 sure is beefy lookin.




Showing a point on the factory C5 caliper adapter. This point makes slight contact with the ebrake backing plate. The caliper adapter still need to be centered just a bit more which would make even more contact with the plate. I need to measure how much of a spacer I need to center it on my axle, maybe have another member (that has a spare axle  laying out) try it out on their axle and see if the spacing is the same. I will probally use that same thickness if its not more than .050. Looking at a dial caliper, it should be less, and use it to space the e-brake plate out just a touch more so only a touch of this bracket will have to be ground down so it doesnt make contact.


Showing the sharpie marks that were made on the inside parking brake drum to see where the contact point is. Entire shoe making contact to the drum with about 1/8" to the end.


All thats left is to find the needed measurement so the caliper is correctly center over the rotor (currently its not), same spacers for the e-brake plate and figure out how to remove the end of the dorman parking brake cable so it can then be shortened. Another member on another board probally had OE cables and the ends "screwed off".... these are crimped. I dont imagine that bing a stupid big deal but once its off, it will be a sinch to shorten the drivers side cable.
The idea on the ebrake cables mod would be so when you run the passenger side cable over the pumpkin and onto the frame rail (as factory) the drivers side shortend cable matches up so you can use factory hardware. Thats the concept.

clint

[modular93fox]

Didnt make much progress today.. had to go into work today Anyway, after searching I found what the vetts use as a E-brake bracket on the hub/knuckle. I pretty much duplicated the design. I need to get the right length before the bend and after the bend and then we are good to go. The bracket will be out of 1/8 flat bar. While searching for this piece, I found a thread that the factory brackets bend and lets the e-brake cables flex more, not holding the car. The guy basically welded 2 gusset like things to make it rigid.. I will probally do something like that aswell... I dont want to fool with it or have anyone else fool with theirs later on down the road.
This shows the piece w/o the gussets.



This is what the brackets alone would look like on the axle flange:



Hopefully the weather is good to me tomarrow and I can make this bracket, and mock up the cables on the rear end and practice brazing the new ferrel onto the modified cable. I also found they sell "swageless" fittings for wire (such as the wire in the ebrake cable). normally the ends are swaged (crimped) on... just another option out there. I am also lacking the intermidate cable. The one that goes from these new rear ebrake cables to the factory one piece. I think this will be an easy fix as the Camaros has a neat equalizer (15.00 new) that looks like it will be a great candidate! Havent bought it yet, but its next on the list.

Clint

[modular93fox]

Finalized the e-brake cable bracket. OE Camaro rear brakes use a cast iron backing plate and the ebrake cable passes through the hole and the fingers on the cable secures it, just like our backing e-brake cables on the trucks. since the metal im using is 1/8, its too thin for the fingers to grab on to and actually old the cable so it doesnt wiggle around. I simply made a holder, just like a distributor hold down bracket. Simple and effective.
On my spare 12 bolt, I found out the wierdest thing. The offsets are not the same... different enough that you have to shim the caliper inwards .10" on one side and outwards .10".. I just happen to have some .10 hardware store washers laying around and happend to be the ideal thickness to center the caliper basket right over the rotor. So I wont be having the brackets milled down to make it a perfect fit, I will just use some hardware store washers to align the baskets.
I was looking at Lokar ebrake cables... dang 119 from summit.... dang any rate, thats an option to make it uber easy but its costly.
clint

[modular93fox]

Update:
ordered axles from Moser with the C-10/Corvette spec.

Stock C-10 c-clip axles
28 spline
2.76 hub (corvette hub od)
OD flange diameter is 6 3/8 (stock is roughly 6.50"
Face of flange steped down to 5.90 and .10 deep

The guys at Moser are real nice and took time to help get the order strait... althought I have to call them back tomarrow becuase I said ".10" and followed that measurement by saying "one thousanth" crap... I hope they didnt ship them already they said I would have them in 6 days.

Clint