okay after a lot of questions asked i finally finished my conversion - and i thought i would share it with everyone - i hope it can help those considering the conversion
i used early 944 single pot brake set up on an irs rear end. You need the calipers, rotors, rubs, caliper carrier, 8 longer bolts to bolt the caliper carrier on, longer rear hard lines, ans swan necks and tubes which rad dubs supplies for the handbrake conversion
first things first - i stripped the calipers, had them shot blast, painted making sure i kept all sliding areas free of paint and replace the piston seal and dust boot - i personally think it is well worth doing and wont cost you much. seals available as a kit from pelican parts
the piston MUST go in completly square and it is a good idea to cover the piston and pot in brake fluid to help ease it in. also u must get the right orientation of the piston - i will post up a good pic i found later
next i moved onto the handbrake mech. you need a special swan neck for the vw handbrake cable as the 944 one is held on with a pin rather than a metal loop. also you need a conversion tube to accept the handbrake condit. i will cover this in a mo
here is the 944 swan neck - the pin needs to be pushed out and put into the new vw friendly swan necks. i used a vice and suitable socket for this. the pin should pop out and in with a little force
now the old tubes for the cable conduit must be removed - this may take some force - soak with some penetrating fluid. then replace with the suitable ones - i used some copper slip also. these new tubes will have to be shortened for your purpose - bus / beetle etc and can be done with the mechanism on the vhicle
bolt the back plate on (you need longer bolts than beetle bolts) and fit all handbrake gubbins. you now need to trim the new cable conduit tube enough to allow the loop of the handbrake cable to fit over the hook on the swan neck - remember its best to chop off to little and readjust than too much! oh and its a good idea to slacken off all ajustment at the handbrake lever end before you do this!
now with the handbrake set up - whack the hub on with hub nut as tight as you can do it by hand - put on the rotor and use the counter sunk screw to hold it to the hub and then bolt on your caliper
i used early 944 single pot brake set up on an irs rear end. You need the calipers, rotors, rubs, caliper carrier, 8 longer bolts to bolt the caliper carrier on, longer rear hard lines, ans swan necks and tubes which rad dubs supplies for the handbrake conversion
first things first - i stripped the calipers, had them shot blast, painted making sure i kept all sliding areas free of paint and replace the piston seal and dust boot - i personally think it is well worth doing and wont cost you much. seals available as a kit from pelican parts
the piston MUST go in completly square and it is a good idea to cover the piston and pot in brake fluid to help ease it in. also u must get the right orientation of the piston - i will post up a good pic i found later
next i moved onto the handbrake mech. you need a special swan neck for the vw handbrake cable as the 944 one is held on with a pin rather than a metal loop. also you need a conversion tube to accept the handbrake condit. i will cover this in a mo
here is the 944 swan neck - the pin needs to be pushed out and put into the new vw friendly swan necks. i used a vice and suitable socket for this. the pin should pop out and in with a little force
now the old tubes for the cable conduit must be removed - this may take some force - soak with some penetrating fluid. then replace with the suitable ones - i used some copper slip also. these new tubes will have to be shortened for your purpose - bus / beetle etc and can be done with the mechanism on the vhicle
bolt the back plate on (you need longer bolts than beetle bolts) and fit all handbrake gubbins. you now need to trim the new cable conduit tube enough to allow the loop of the handbrake cable to fit over the hook on the swan neck - remember its best to chop off to little and readjust than too much! oh and its a good idea to slacken off all ajustment at the handbrake lever end before you do this!
now with the handbrake set up - whack the hub on with hub nut as tight as you can do it by hand - put on the rotor and use the counter sunk screw to hold it to the hub and then bolt on your caliper