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Old 08-10-2007, 04:03 PM   #1
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Default How to: 944 n/a Rear discs

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

http://img.photobucket.com/albums/v1...DSC00447-1.jpg

[img]http://img.photobucket.com/albums/v1...e/DSC01262.jpg[/img]

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

http://img.photobucket.com/albums/v1...e/DSC01263.jpg

http://img.photobucket.com/albums/v1...e/DSC01265.jpg

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

http://img.photobucket.com/albums/v1...e/DSC01285.jpg

http://img.photobucket.com/albums/v1...e/DSC01286.jpg

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!

http://img.photobucket.com/albums/v1...e/DSC01287.jpg

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

http://img.photobucket.com/albums/v1...e/DSC01289.jpg
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Last edited by dub_crazee; 10-10-2007 at 12:23 PM..
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Old 08-10-2007, 04:04 PM   #2
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http://img.photobucket.com/albums/v1...e/DSC01290.jpg

now you need to use a longer hardline (mine was 675mm off the top of my head but PLEASE check) i got mine made up for the grand sum of 8 the porsche calipers use same unions as beetles

http://img.photobucket.com/albums/v1...e/DSC01292.jpg

bleed up your brakes and torque the rear hub nut - u are now done. happy days - porsche 944 brakes

http://img.photobucket.com/albums/v1...e/DSC01293.jpg

http://img.photobucket.com/albums/v1...e/DSC01301.jpg

enjoy
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Last edited by dub_crazee; 10-10-2007 at 12:19 PM..
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Old 08-10-2007, 08:24 PM   #3
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Glad you liked the conduits and swan necks.
More are in production as we speak, I'll be selling them as a set for 45 posted, if anyone is inspired by Dubcrazees cool pictorial.
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Old 08-10-2007, 08:49 PM   #4
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nice work im doing this at the mo you have just answerd some questions for me

andy
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Old 08-10-2007, 09:50 PM   #5
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of no use to me as i'm not doing this, but think what you have done is great and we need more topics like this. think things like this will help a lot of people out, nice work.
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Old 08-10-2007, 10:00 PM   #6
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When I get the final photos up I'll do the front pre 85 conversion and get all the diagrams up too.

Deano: You beat me to it. Getting back to uni has taken priority.

FYI the Porsche tubes can be used with adapters, however the cables are a bitch to get in. I've reamed my tubes out a bit. Rad Dub's tubes are probably a better solution, but weren't available at the time of conversion. I can't recommend enough the guy who I got all my bits from in Canada from www.veedubengineering.com

I'll get the conversion up soon, then a sticky may be in order
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Old 08-10-2007, 10:15 PM   #7
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Quote:
Originally Posted by al_kaholik View Post
When I get the final photos up I'll do the front pre 85 conversion and get all the diagrams up too.

Deano: You beat me to it. Getting back to uni has taken priority.

FYI the Porsche tubes can be used with adapters, however the cables are a bitch to get in. I've reamed my tubes out a bit. Rad Dub's tubes are probably a better solution, but weren't available at the time of conversion. I can't recommend enough the guy who I got all my bits from in Canada from www.veedubengineering.com

I'll get the conversion up soon, then a sticky may be in order

i cant get that link to work is it correct thanx

andy
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Old 08-10-2007, 10:18 PM   #8
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glad u guys liked it i also did one on adjusting rear suspension not long ago - would be cool if these things could be archived and not lost!

al - ive been waiting a month to put this up what with moving back to uni and vzi crashing! itl be good to see the front conversion! the only hing that puts me off is the cost.

rad dubs stuff is good and works really well - i noticed when i was playing around with the 944 stuff the cable was a real pain to get into the 944 tube!

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Old 08-10-2007, 10:30 PM   #9
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sorry link is www.vdubengineering.com

Front will cost a lot less if yo get a local engineer to do it. It cost me a hell of a lot less than I was expecting. Just the caliper plates to have made/make as I've now found a metal supplier who will cut to rough shapes. A friend has a beefy angle grinder too, and the correct drills and tap so I may just make them up myself to reduce the cost
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Old 08-10-2007, 10:48 PM   #10
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I could get them laser cut pretty cheaply, if enough people, say 5 wanted a pair.
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