After all the previous measuring I realised that using only one spacer behind the inner bearing to take up the 8.5 mm lateral play would push this bearing off the flat running surface and over the tapered portion of the spindle, so I decided to (ask my kind, old school engineering uncle with cool 40 year old tools, at the cost of a portion of fish and chips to) turn down the inner spacer 6.5mm thick with a taper to allow for the spindles' inner radius. This slid on with a slight tap and allowed the inner bearing seal to sit on the original face and gave me a gap of 9mm behind the disc to fit onto the original wheel cylinder mounting holes a mounting plate for the calliper.
The vision of a shiney Fusch wheels and polished callipers isn’t as easy to pull off as “oh you need some 944 hubs to do that” Its hard to get the right parts when you don’t know the model and year of the car, you cant just ask for a rear disc with about this much diameter and the depth to fit the rusty hub you plonk on the counter, But the bloke at the parts shop was intrigued with what I was trying to do and was very helpful pulling parts off the shelf’s till I found what I thought would fit.
I like (more stare at each time I see one) the 996 / Boxster style of Porsche mono block (all once piece) callipers but these are for 320ish mm diameter discs to fit 16”+ wheels and would be to much trouble to fit in my 15”ers So the power of eBay drew me into it's grasp for a month while I tried to obtain a set of 944/924 Brembo callipers for a fair price (Inc postage). Of course the description is not always accurate. What I received needed a full check up. this included freeing a couple of pistons new dust seals and some corrosion treatment.
During my clean up and inspection it became apparent I'll have to sort a few things out. There was corrosion around one off the pistons holes that will need blasting to remove it and that piston was seized, this was because of corrosion on the surface. I found out after I levered it out that there’s a removal tool that probably makes the job a lot easier. Also the piston sizes weren’t matching and the rotation arrow was the same. Each calliper is manufactured with two different size pistons, the smaller of the two at the leading edge. I ended up with a pair of 36mm-40mm that Ill use for the front but have a right hand 32mm-36mm and a right hand 30mm-34mm. This is the problem of doing things on a budget, you get what you pay for. I'll look for something better later but for now they will help me get everything fitted OK.
Fitting the calipers’ to the rear 924 swing arms should be a bit easier than messing around with bearing spacers. With new discs trialed on and the calipers pads centered on these, I’m able to work out the spacing between the original caliper attaching threads on the rear swing arms and the calipers. If I sit the caliper so the pads are on the center of the disc it foul's the disc on the lower part of the caliper, and because the rear hubs came with out rotor attaching parts (two counter sunk disc fixing screws) Ill need to sources these to get the disc fixed securely so that the measurements I need to adjust the caliper are correct.
If I fit the caliper to the original mounting threads on the rear swing arm the pads over lap the disc. The easiest way to solve this is hope there a wider disc with the same offset for the hand brake drum assembly. I think the Brembro calipers are fitted to turbo 944 so that could be an option, although that may mean a bigger disc off set for larger turbo style wheels. I'll have to have a chat with the parts shop again and see if they have any thing that will help.
Grabbing a few spare bit of pallet wood I knocked up a front caliper mounting bracket this gives me a visual idea of the calculations and drawings I've been spreading around the garage on each piece of scrap paper I could find, With a bit of fine tuning. I'd like to get this part CNC (Computer Numerical Control) machined at a local shop, but if its to expensive Ill make it from plate steel and weld on and tap the spacers/ mounting holes. All of this and I still need to work out how to pressurise this lot? I'm sure the original single circuit master cylinder wont be up for it!
After all the previous measuring I realised that using only one spacer behind the inner bearing to take up the 8.5 mm lateral play would push this bearing off the flat running surface and over the tapered portion of the spindle, so I decided to (ask my kind, old school engineering uncle with cool 40 year old tools, at the cost of a portion of fish and chips to) turn down the inner spacer 6.5mm thick with a taper to allow for the spindles' inner radius. This slid on with a slight tap and allowed the inner bearing seal to sit on the original face and gave me a gap of 9mm behind the disc to fit onto the original wheel cylinder mounting holes a mounting plate for the calliper.
The vision of a shiney Fusch wheels and polished callipers isn’t as easy to pull off as “oh you need some 944 hubs to do that” Its hard to get the right parts when you don’t know the model and year of the car, you cant just ask for a rear disc with about this much diameter and the depth to fit the rusty hub you plonk on the counter, But the bloke at the parts shop was intrigued with what I was trying to do and was very helpful pulling parts off the shelf’s till I found what I thought would fit.
I like (more stare at each time I see one) the 996 / Boxster style of Porsche mono block (all once piece) callipers but these are for 320ish mm diameter discs to fit 16”+ wheels and would be to much trouble to fit in my 15”ers So the power of eBay drew me into it's grasp for a month while I tried to obtain a set of 944/924 Brembo callipers for a fair price (Inc postage). Of course the description is not always accurate. What I received needed a full check up. this included freeing a couple of pistons new dust seals and some corrosion treatment.
During my clean up and inspection it became apparent I'll have to sort a few things out. There was corrosion around one off the pistons holes that will need blasting to remove it and that piston was seized, this was because of corrosion on the surface. I found out after I levered it out that there’s a removal tool that probably makes the job a lot easier. Also the piston sizes weren’t matching and the rotation arrow was the same. Each calliper is manufactured with two different size pistons, the smaller of the two at the leading edge. I ended up with a pair of 36mm-40mm that Ill use for the front but have a right hand 32mm-36mm and a right hand 30mm-34mm. This is the problem of doing things on a budget, you get what you pay for. I'll look for something better later but for now they will help me get everything fitted OK.
Fitting the calipers’ to the rear 924 swing arms should be a bit easier than messing around with bearing spacers. With new discs trialed on and the calipers pads centered on these, I’m able to work out the spacing between the original caliper attaching threads on the rear swing arms and the calipers. If I sit the caliper so the pads are on the center of the disc it foul's the disc on the lower part of the caliper, and because the rear hubs came with out rotor attaching parts (two counter sunk disc fixing screws) Ill need to sources these to get the disc fixed securely so that the measurements I need to adjust the caliper are correct.
If I fit the caliper to the original mounting threads on the rear swing arm the pads over lap the disc. The easiest way to solve this is hope there a wider disc with the same offset for the hand brake drum assembly. I think the Brembro calipers are fitted to turbo 944 so that could be an option, although that may mean a bigger disc off set for larger turbo style wheels. I'll have to have a chat with the parts shop again and see if they have any thing that will help.
Grabbing a few spare bit of pallet wood I knocked up a front caliper mounting bracket this gives me a visual idea of the calculations and drawings I've been spreading around the garage on each piece of scrap paper I could find, With a bit of fine tuning. I'd like to get this part CNC (Computer Numerical Control) machined at a local shop, but if its to expensive Ill make it from plate steel and weld on and tap the spacers/ mounting holes. All of this and I still need to work out how to pressurise this lot? I'm sure the original single circuit master cylinder wont be up for it!
