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Upgrade Front Calipers/carriers & Discs


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Finally got Sunday Morning to look at the kit and managed to test fit the bigger break options I sourced from the local tat yard.

 

 

1_zpspre1heq4.jpg

 

Old Calipers & 240mm discs:

 

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Test Caliper & 280mm discs:

 

4_zpsplpscxbf.jpg

 

6_zpsq0t80p72.jpg

 

Stripping Calipers/Carriers down for refurb:

 

7_zpshzwrb7cv.jpg

 

Big difference in Disc, Caliper and Pad size:

 

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Old pistons:

 

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Cleaned & Painted while I await all the parts to be delivered:

 

9_zpsxnyxbce3.jpg

 

 

 

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Take your pick - Ford Cougar, Cosworth RS500. Granada Cosworth or in my case Mondeo V6 Mk1.

 

Either get the 278mm discs skimmed and fit 10mm Spacers on the carrier to centre them.

 

Or

 

Cut down 283mn discs from Cosworth to 278mm and fit 2mm spacer (as they are wider).

 

Just waiting on the shiny bits to come thru the post to complete the set-up.

 

You could go bigger (300mm) using Mondeo Mk3 calipers but u would really need 17" wheels for them to fit - Also think it's overkill

Edited by Dino
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Done a little bit more work last night refurbishing the calipers:

 

IMG_8160_zpsvjcr4xsi.jpg

 

IMG_8167_zpskqr6owhu.jpg

 

Drilling the M12 holes:

 

IMG_8170_zpsjbk1wkaj.jpg

 

Test fitting the calipers with the new bolts and spacers:

 

IMG_8171_zpsrocxhshk.jpg

 

Hmmmm....high tensile bolts are 2mm to long, so plonked in a washer, then pondered how to ratchet top hex socket?

As extensions and knuckles catch on the nut & bolt:

 

IMG_8173_zpsz9udzljf.jpg

 

So they look OK and centred/ran freely when the test disc was fitted:

 

IMG_8179_zpsd7oxz0bv.jpg

 

 

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Can you change bolts to 10.9 cap head?

 

I have thought about a M12 flanged hex bolt (as they are available at 10.9), but need to confirm with Ford what the original M10 threads are?

Unless some knowledgeable person on here knows what the original M10 threads are, holding the carriers?

(I cannot read the top of the original bolt heads to see what strength they were.)

 

But yes, I like your thinking if this makes fitting them easier. :)

Edited by Dino
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EDIT:

 

After test fitting last night , found that the spacers need to be the following:

  • O.D: 25mm
  • I.D: 12mm
  • Thickness: 12mm (not 10mm as originally thought.)

Bolts are M12 high tensile (12.9) 40mm, but required a 2mm washer to fit correctly :

  • Do I cut bolts down to 38mm (+ added pain of tightening the top bolt)
  • Get M12 flanged high tensile bolts (but only available up to 10.9 and awaiting confirmation if this is adequate?)
Edited by Dino
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Quick dig around and found this (M10 high tensile bolts (10.9) for calipers):

 

http://www.fordpartsuk.com/shop/ford_m10_x_25mm_caliper_bracket_bolt_f_1471746_c_1588.htm

 

....If its good enough for Ford, then its good enough for me.

Time to order the M12 flanged high tensile (10.9) bolts and take the easy route to fitting :)

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I researched al this last year prior to selling my 2B and the best caliper to get seemed to me to be the Fiesta ST150 as the carriers were a direct bolt on swap with M10 bolts so no need to drill out the mounting holes. Just about all the other calipers are M12 as above unless you can get hold of some 2wd Cosworth items.

I actually advertised the ST carriers on here after selling up, but there was no interest so put them in the scrap bin at the tip.

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Finished up this morning and completed both front brake calipers, carriers, pads and discs:

 

M12 holes drilled:

 

IMG_8170_zpsjbk1wkaj.jpg

 

High tensiles 10.9 M12 bolts cut down from 40mm to 36mm and fits perfectly with the M12 x 10mm thick spacers:

 

10_zpsjhfgvgu5.jpg

 

Ooooooo big & shiney & new mintex pads:

 

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Fits nice and snug and moves freely (better than originals):

 

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Wheels on and next bleed the system and bed them in before the MOT:

 

13_zpsse3d8xof.jpg

 

A very satisfying job and next on the agenda will be the rear disc conversion.

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EDIT:

 

After test fitting last night , found that the spacers need to be the following:

  • O.D: 25mm
  • I.D: 12mm
  • Thickness: 12mm (not 10mm as originally thought.)

Bolts are M12 high tensile (12.9) 40mm, but required a 2mm washer to fit correctly :

  • Do I cut bolts down to 38mm (+ added pain of tightening the top bolt)
  • Get M12 flanged high tensile bolts (but only available up to 10.9 and awaiting confirmation if this is adequate?)

 

 

Just to confirm if anybody was interested:

 

I managed to get everything running smoothly with little effort using the following:

 

Mondeo V6 Mk1 carriers, calipers and test discs from the tat yard

New Mintex pads and discs for Mondeo V6 Mk 1

Flanged M12 x40mm (high tensile 10.9) bolts cut down to 36mm

Caiper refurbish kit

Spacers

  • 25mm O.D
  • 12mm I.D
  • 10mm Thick

Didn't break the bank and a third of the price of any equivalent big brake kit , great learning curve and hopefully fingers crossed they work :)

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