30psi mk2 cortina
6th February 2009, 12:17 AM
some time ago i was making caliper mounts up to make my wilwood calipers fit onto my falcon (borg warner) diff backing plates.
After having a few questions as to how i made my front caliper mounts up i decided to take pics of the process and post them for all to see and mabe pic up some tips.
Now i know not everyone will be mounting the same calipers to the same diff or have the use of the machines etc but you can get a good idea of how to start and what to do in general for mounting calipers.
This is the caliper in question
http://img153.imageshack.us/img153/2042/20071031358tg0.jpg
Well this is how i started.......
The first thing is to sit the caliper onto the disc and work out the center spacing /offset.. You need to make sure that the caliper sits in the middle off the disc.
In my case with this setup i was about 2.5mm out of center meaning i needed to make a change to something.
I decided to take the material off of the backing plate as the was sufficent meat on the backing plate for me to do so.
Taking the 2.5mm off of the backing plate would mean that my caliper would be aligned perfectly centered.
http://img165.imageshack.us/img165/8388/20071026329gu4.jpg
Once the caliper was centered i could now turn my attention to actually creating the mounting bracket to adapt from the ford 71mm bolt spacing to the wilwood caliper 95mm bolt spacing.
What i did was put the pads in the caliper and also put a piece of card board behind each pad ( to take up the pad slack as the piston was pushed all the way backin the caliper)so that when i slid the caliper onto the disc it would be a tight fit and hold the caliper centered onto the disc and not let it move around too much while i marked / measured stuff out for the brackets.
http://img155.imageshack.us/img155/107/slide1gz9.jpg
At this stage i now had the caliper centraly mounted on the disc and now started to make some spacers up so that i could use a flat piece of 10mm steel to create the caliper mounting bracket.
The wilwood caliper mounting plate is 11mm thick . so i needed to make up some 11mm spacers to go on the ford backing plate so that in the end the caliper would sit flush with the spacers.
I found some 20mm pipe with a 4mm wall and the perfect 12mm ID for the caliper bolts ........ Lucky me !! So all i had to do was part them off on the lathe. ( could use a hack saw or grinder if a lathe is not accessable ;) )
http://img340.imageshack.us/img340/9198/20071026330di7.jpg
The next challenge i faced was getting the caliper to sit far enough on the disc so that i could use the spacers and still access the mounting holes in the backing plate.
( hard to understand ?? hopefully the pics help ;) )
http://img160.imageshack.us/img160/6741/slide3tm7.jpg
Here is a pic of the spacers in the mill and what the came out like when finished.
http://img516.imageshack.us/img516/9674/slide4ze7.jpg
I know not everyone has access to a mill also so a simple grinder would do the trick here. ;)
Now with this done it is time for the next step in the process. Making a template for the actual mounting bracket.
For this I just simply start with a piece of carboard. I traced out the piston shape of the caliper and cut it out so that i could align the mounting holes.
http://img528.imageshack.us/img528/592/20071030343ds9.jpg
After having a few questions as to how i made my front caliper mounts up i decided to take pics of the process and post them for all to see and mabe pic up some tips.
Now i know not everyone will be mounting the same calipers to the same diff or have the use of the machines etc but you can get a good idea of how to start and what to do in general for mounting calipers.
This is the caliper in question
http://img153.imageshack.us/img153/2042/20071031358tg0.jpg
Well this is how i started.......
The first thing is to sit the caliper onto the disc and work out the center spacing /offset.. You need to make sure that the caliper sits in the middle off the disc.
In my case with this setup i was about 2.5mm out of center meaning i needed to make a change to something.
I decided to take the material off of the backing plate as the was sufficent meat on the backing plate for me to do so.
Taking the 2.5mm off of the backing plate would mean that my caliper would be aligned perfectly centered.
http://img165.imageshack.us/img165/8388/20071026329gu4.jpg
Once the caliper was centered i could now turn my attention to actually creating the mounting bracket to adapt from the ford 71mm bolt spacing to the wilwood caliper 95mm bolt spacing.
What i did was put the pads in the caliper and also put a piece of card board behind each pad ( to take up the pad slack as the piston was pushed all the way backin the caliper)so that when i slid the caliper onto the disc it would be a tight fit and hold the caliper centered onto the disc and not let it move around too much while i marked / measured stuff out for the brackets.
http://img155.imageshack.us/img155/107/slide1gz9.jpg
At this stage i now had the caliper centraly mounted on the disc and now started to make some spacers up so that i could use a flat piece of 10mm steel to create the caliper mounting bracket.
The wilwood caliper mounting plate is 11mm thick . so i needed to make up some 11mm spacers to go on the ford backing plate so that in the end the caliper would sit flush with the spacers.
I found some 20mm pipe with a 4mm wall and the perfect 12mm ID for the caliper bolts ........ Lucky me !! So all i had to do was part them off on the lathe. ( could use a hack saw or grinder if a lathe is not accessable ;) )
http://img340.imageshack.us/img340/9198/20071026330di7.jpg
The next challenge i faced was getting the caliper to sit far enough on the disc so that i could use the spacers and still access the mounting holes in the backing plate.
( hard to understand ?? hopefully the pics help ;) )
http://img160.imageshack.us/img160/6741/slide3tm7.jpg
Here is a pic of the spacers in the mill and what the came out like when finished.
http://img516.imageshack.us/img516/9674/slide4ze7.jpg
I know not everyone has access to a mill also so a simple grinder would do the trick here. ;)
Now with this done it is time for the next step in the process. Making a template for the actual mounting bracket.
For this I just simply start with a piece of carboard. I traced out the piston shape of the caliper and cut it out so that i could align the mounting holes.
http://img528.imageshack.us/img528/592/20071030343ds9.jpg