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my modified campaign project.

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Having decided to go back to the g60 type brakes i  thought i would attempt something slightly different.     The g60 calipers are now pretty old and prices are quite steep.    Having run a clio 172 for the past 7 years i knew they run a 280mm front brake with lucas 54 calipers which are very similiar to the g60 calipers,   Unfortunately i gave away my accumulated spares when i recently sold the clio so a look on ebay got me a pair of 182/172 calipers/carriers for the princely sum of £40 delivered, these also have the advantage of being rather newer. So my plan (may not work) is to make an adaptor to fit these to the mk1 golf hub.      I dont have access to a machine shop just hand tools so nothing too intricate.  I just happen to have a piece of alloy which i will use (easy to work with) and if successfull will then buy some steel to make the final piece with, for strength obviously.

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So i have made the trial alloy bracket, the final steel one will be shaped, not left as a rectangle. Bolting it all together it all seems to be in the right place..That is a 280mm g60 disc.. n.† † † † † † † † † Edit† † So having a garage full of expensive parts and with the small amount of time i work on it i just got fed up and have given up on this for now,† have sold most of my parts of. Did consider selling the shell but as i had zero interest last time i advertised it i will keep it for now. EDIT EDIT,,† PROBABLY GOING TO HAVE ANOTHER GO AT GETTING THIS RUNNING AND USING IT,† MANY PARTS TO BUY AGAIN.

Last edit: by abfmk1

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So decided i have to carry on with this really, sold lots of parts but most can be bought again. However the part i cannot easily buy is the south african brake bar that i sold, so decided to make one. The brackets shown in photo are not bolted on so may look crooked. All i have left to do is assemble it so i can work out where the arms need to be welded on the bar in relation to each other, and paint it up. The actual long bar and white bush,s are† an escort part (although the arms are mine, ground the originals of)) and its the exact length required.

Last edit: by abfmk1

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SA brake bar copy is now finished, pretty sure it will work better than the original push pull push system and fitted with my brand new (expensive ) 16v type servo.
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Not particularly good photos i know.., and there is a gap between heater hoses/bar.

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Time to get back to the 280mm brake conversion, brackets in particular.   Originally i tried to make these from 6mm thick stainless but it was just too hard for my hand tools,  wasted a lot of time and so went to 6mm mild steel, much easier to work with,  just have to give them a coat of paint.  Photos should show calipers/carriers on their way to being 100% rust free,  then painted up  and the brackets. Will be assembled with new pistons, seals, sliders, nipples and hoses.

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Looking good  :thumbs:

I know what you mean about Stainless, just trying to drill a hole with carbide bits was a struggle on my stainless downpipe. In the end I had to attack it with a die grinder!

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Loving your work on the brake bar. Such a simple design makes you wonder why VW went with such a complex set-up in the first place. Parts costs and assembly time would have been much reduced!

My rebuild thread I will try and keep up to date:†here

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paceman said

Loving your work on the brake bar. Such a simple design makes you wonder why VW went with such a complex set-up in the first place. Parts costs and assembly time would have been much reduced!

Think the in-period Autocavan upgrade was similar.

It seems to be the method used by many manufacturers to convert from LHD to RHD without having to move the brake master cylinder, servo+ vac hoses and all the ABS and brake pipe plumbing from one side of the engine by to the other.

Over the years I've helped out friends and noticed that their cars had such a brake bar, Ford Puma and†Fiat Seicento for example and nobody ever complains their brakes are cr P ?

1983 Mars Red 1.8 Golf GTI
1987 Alpine White 1.8 Clipper Cabriolet

The trouble with doing nothing is that you never know when you are finished.

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quality work, keep it up!

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Impressive work !!!  :)

LIGHTER IS† FASTER !!!

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Originally i bought a set of b4 bilstein shocks, but thought they were possibly better suited to a standard mk1, so have bought a pair of adjustable konis for the front,  bilstein b6 for the rear and uprated / thicker anti roll bars.  Another £750 plus to sit around in the garage.
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