Polo Disc Brake Conversion

Post by **jonathon** » Mon Nov 27, 2006 8:28 pm

I'd check where the discs are produced before parting with even the smallest amount of money,there are some pretty poor specimens on the market at the moment usefull only for use as door weights. To remachine the correct PCD and center bore should cost no more than £8-10, but will depend on how many are done at a time. Some engineering shops do shy away from brakework especially modifications to components, for reasons I aluded to in a previous post.
Caliper brackets would be around £6-8each plus the milling.

Post by **plastic_orange** » Mon Nov 27, 2006 8:50 pm

There you go

Pete

Post by **Peetee** » Mon Nov 27, 2006 8:58 pm

Peetee - the SEAT is effectively a VW Lupo and the discs are that size

Yes I know. All the small capacity VW derivatives use the 239mm discs. But I still draw on the original question. Is this modification based on the fitment for the original Polo discs or can it work for the '83 onwards models with VW calipers? That bracket might work for an early caliper but will it work on a later one? Sorry to push this but it's a very valid question and if answered will make this conversion far more accessable and affordable.

Post by **jonathon** » Mon Nov 27, 2006 9:07 pm

Peetee, Id go with the later VW calipers and make/have made a caliper bracket made to suit, easy enough if you know how.

Post by **bmcecosse** » Tue Nov 28, 2006 7:22 am

Surprisingly cheap price you suggest for caliper brackets Jonathon. Is that an offer to supply brackets at that price ? And I quite agree - £4.12 for a disc hardly suggests a high quality item!! Peetee - the answer would be to make a quick mock-up of the bracket in wood (as shown earlier in the 'Ford' thread) to see how your caliper sits before getting them made in steel.

Post by **Peetee** » Tue Nov 28, 2006 11:10 am

Ah, if only I had the time

My carport is currently 6 weeks in the making and only 1/3 finished.

Post by **bmcecosse** » Tue Nov 28, 2006 1:02 pm

You can whittle away at it during the long dark evenings!

Post by **lalaw** » Tue Nov 28, 2006 1:05 pm

Note! the discs should be for Polo type 1 75 - 81.
If you need drawings of the disc you check brembo site:
http://www.brembo.com/CatalogoBrembo/De ... 08.2878.10
later polo have these discs and the depth is different so the caliper won't fit.
http://www.brembo.com/CatalogoBrembo/De ... 08.2631.30
Orignal articale says that caliper from polo 75-81 should be used but I will use Golf typ 1 calipers (ATE) and they seem to fit just fine.
Br Lars

Post by **lalaw** » Tue Nov 28, 2006 1:09 pm

As I mentioned before the Brembo discs are cheap about 20 euro each atleast here in sweden.
Br Lars

Post by **plastic_orange** » Tue Nov 28, 2006 2:02 pm

I've sent mate the drawings, and he will be costing shortly. I would suggest that anyone who wants a pair should approach him directly if price is ok.
A word of caution though - are the drawings accurate?, as mate can take no responsibility if they don't fit. I would suggest a 'guinea pig' to try them out, then report back (not me - I don't need them).

See: www.bespoke-bits.co.uk

Pete

Post by **lalaw** » Tue Nov 28, 2006 2:18 pm

From the drawing I posted I made a prototype in wood and it fitted perfectly.

And with the disc on.

Br Lars

Post by **bigginger** » Tue Nov 28, 2006 3:39 pm

Excellent work. Well done that man. I spy a trend starting

Post by **JimK** » Tue Nov 28, 2006 5:04 pm

I think you need to remember it's wood and replace it with a steel one before driving

Post by **jonathon** » Tue Nov 28, 2006 6:54 pm

Caliper brackets £25 each but only as a batch of 50, plus plating ,vat and carriage.
As mentioned no responsibility is taken for incorrect dimensions , so I agree a demo/trial would be required.

Post by **bmcecosse** » Tue Nov 28, 2006 7:45 pm

lalaw - one pic you have the caliper 'trailing' - next you have it 'leading' - was there a reason why the trailing position was not possible ? Seems a fair price Jonathon - slightly less than I had 'guesstimated' in my head - but will you get a batch order for 50 pairs I wonder ! Are the brackets 'handed' in any way - or can they just be used on either side as they are ?

Post by **lalaw** » Tue Nov 28, 2006 7:55 pm

I discovered that it was easier routing the brakehose, but it works both ways.
Br Lars

Post by **wanderinstar** » Tue Nov 28, 2006 8:04 pm

Jonathon,
One minute.
Caliper brackets would be around £6-8each plus the milling. icon_wink.gif
Next minute.
Caliper brackets £25 each but only as a batch of 50, plus plating ,vat and carriage.

That's about a 300% increase in less than 24hrs.

Post by **bmcecosse** » Tue Nov 28, 2006 8:08 pm

Maybe there is a 'lot' of milling !!

Post by **jonathon** » Tue Nov 28, 2006 8:22 pm

Ian, the £6-8 was my guestimate, based on the sort of laser cutting I have done. The price today is the actual cost from my manufacturer.
I'm not even offering to have these parts made Ian, it was an offer of information. To be perfectly honest the cost is pretty reasonable, if a member of the public and not a trader had made this enquiery then the cost would have exceeded £35 per bracket. The major cost of the bracket is the taping of the M10 holes and the setting up and milling operation. Hope this helps you to understand the pricing.

Post by **bmcecosse** » Tue Nov 28, 2006 8:28 pm

We could tap our own holes easily enough! Do we know yet if the brackets need to be 'handed' - it seems to me the reduced thickness part where the caliper mounts (presumably to line it up squarely over the disc) (and presumably the 'milling' operation) will make the bracket handed. Or am I missing something ?