Hilux rear disc brake conversion

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Postby siringo » Thu Mar 20, 2008 4:39 pm

Sounds great DGR. What have you done for a handbrake??
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Postby Mr DJ » Thu Mar 20, 2008 8:30 pm

Thanks Greg, don't spose you know what the offset of the rotors were ???
Are they a different offset to IFS rotors ?

I happen to have a pair of these left over from the SAS, IFS slotted front rotors (DBA780S) ....

Image

hoping to use them as they are virtually brand new still (21/22mm currently and minimum size is 18mm). Will have to make the centre hole a bit bigger to fit tho.

Finding the right volume caliper with hand brake will be the tricky bit me thinks.

I don't have a spare rear axle housing to set everything up on, anyone have one laying around I could borrow ??
"There are a number of mechanical devices which increase sexual arousal, particularly in women. Chief among these is a Pumped Up Surf."

91 Hilux Surf, with a few extra's ....
SAS by http://www.budscustoms.com.au
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Postby 4runnernomore » Fri Mar 21, 2008 1:39 pm

Mr DJ,

I have an 85 model rear axle housing ATM in the shed. Unfortunately it is in Sydney.

cheers, Chris
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Postby Mr DJ » Fri Mar 21, 2008 3:08 pm

Thanks for the offer Chris, but think the frieght here and back might be a bit exxy.
"There are a number of mechanical devices which increase sexual arousal, particularly in women. Chief among these is a Pumped Up Surf."

91 Hilux Surf, with a few extra's ....
SAS by http://www.budscustoms.com.au
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Postby tufflux87 » Wed Sep 02, 2009 6:36 pm

hi i am new to this site and i have the same problem ....i need to convert to disc rear only to handle the chev 305 i am bout to drop in her its not a 4x4 but a 2x4 can any one help with this please ??
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Postby Mr DJ » Wed Sep 02, 2009 10:45 pm

I would think the rear axle setup on a 2WD would be similar to the rear on a 4WD, so if that's the case, the 4WD disc rear conversions should work fine for you.
There have been a few done, some working better than others, tho none of the others I have seen have the hand brake on the caliper which is required for engineering approval.

The setup I'm working on uses GQ rear rotors, Subaru "L" series front calipers (these suby's have the hand brake on the front caliper), and still need to find an early Prado master (disc F&R) & booster so it all bolts up & works well ...... I hope.
"There are a number of mechanical devices which increase sexual arousal, particularly in women. Chief among these is a Pumped Up Surf."

91 Hilux Surf, with a few extra's ....
SAS by http://www.budscustoms.com.au
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Postby andyjim243 » Wed Sep 02, 2009 10:57 pm

Mate of mine just did this conversion,but used a 45 series Master cyl,1 1/8" cast iron bore.

http://locktup4x4.com.au/hilux-solid-front-78/brake-81/rear-disc-brake-conversion-kit-260.html


http://locktup4x4.com.au/hilux-solid-front-78/brake-81/1-bore-master-cylinder-246.html

http://locktup4x4.com.au/hilux-solid-front-78/brake-81/transfer-case-park-brake-245.html

Locktup are putting together a kit that allows you to source your own calipers,to help keep cost down.Should be available soon.
Cheers Andy
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Postby Mr DJ » Wed Sep 02, 2009 11:32 pm

andyjim, good find tho that's no good if you want to run it engineered on the road as they use hilux front calipers and a transfer mounted hand brake.

Handbrake must be at both rear wheels and transfer/drive shaft brakes are not roadworthy unless as std equipment from the factory, not to mention that's a bit expensive for what you get IMO ... $1668 + fitting/mods, my setup is less than $300 so far and includes caliper kits and a spare housing to mock it up on .... just need to find the time to get it all put together ;)
"There are a number of mechanical devices which increase sexual arousal, particularly in women. Chief among these is a Pumped Up Surf."

91 Hilux Surf, with a few extra's ....
SAS by http://www.budscustoms.com.au
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Postby tufflux87 » Thu Sep 03, 2009 5:44 am

mr.dj thank you for sharing can i ask ? did you buy your calipers in a kit ?? can i ask where?
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Postby andyjim243 » Thu Sep 03, 2009 8:31 pm

Mr DJ wrote:andyjim, good find tho that's no good if you want to run it engineered on the road as they use hilux front calipers and a transfer mounted hand brake.

Handbrake must be at both rear wheels and transfer/drive shaft brakes are not roadworthy unless as std equipment from the factory, not to mention that's a bit expensive for what you get IMO ... $1668 + fitting/mods, my setup is less than $300 so far and includes caliper kits and a spare housing to mock it up on .... just need to find the time to get it all put together ;)


Yeah Mr DJ,I understand what you are saying.
Alot of people don't know how to do all the mods themselves and bolt it up correctly,let alone custom up their own brackets,etc.So I whacked up a few links for them,to give them ideas.As for the park brake,comp and weekend warriors use them,I wouldn't hesitate using one, even if I had to run two seperate levers. (one for rear wheels and one for transfer).You know what those clowns at the RTA say 'safety first',he he he
Personally I like the Scubby front caliper set-up because of the well sealed park brake mechanism that stops mud/water/sand jamming it up (un-like the falcon caliper) and the big vented GQ rotor,and like you say,nice and cheap!!!
You should put up some pics,so we can see your set-up.
A mate of mine has done the same thing,but hasn't decided on m/cyl yet.
Cheers Andy
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Postby andyjim243 » Thu Sep 03, 2009 8:36 pm

Image
Click on the little box with the red x in it
DJ YOU SHOULD KNOW THIS TRUCK,IT'S SHANES SAS,NOW WITH SURF COILS.
I have the inboard rear leaves now.
People,This is the brake set-up DJ is doing.
Cheers Andy
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Postby Mr DJ » Thu Sep 03, 2009 11:13 pm

andyjim243 wrote:Image
Click on the little box with the red x in it
DJ YOU SHOULD KNOW THIS TRUCK,IT'S SHANES SAS,NOW WITH SURF COILS.
I have the inboard rear leaves now.
People,This is the brake set-up DJ is doing.
Cheers Andy


Yea, that's it Andy :thumbsup:
Shane's rig is well done, and should go very well with the new mods to the rear.

As for master, can use the existing setup with a willwood bias valve, but IMO a better way to go is an early Playdo booster & master, have not yet sourced mine so not 100% sure from which model.
"There are a number of mechanical devices which increase sexual arousal, particularly in women. Chief among these is a Pumped Up Surf."

91 Hilux Surf, with a few extra's ....
SAS by http://www.budscustoms.com.au
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Postby Mr DJ » Sun Sep 06, 2009 8:01 pm

tufflux87 wrote:mr.dj thank you for sharing can i ask ? did you buy your calipers in a kit ?? can i ask where?


Sorry tufflux, the calipers I bought from the wreckers (took them off the car) and then sourced a seal kit for it.
"There are a number of mechanical devices which increase sexual arousal, particularly in women. Chief among these is a Pumped Up Surf."

91 Hilux Surf, with a few extra's ....
SAS by http://www.budscustoms.com.au
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Postby andyjim243 » Mon Jan 25, 2010 11:59 am

What's the latest Doug? I've started gathering parts.....
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Postby Mr DJ » Mon Jan 25, 2010 10:24 pm

Not much further unfortunately Andy :redface:.
Few pics of it mocked up on the spare housing.

Image
Image
Image


DOH ..... have just noticed a bit of a problem .... where is the shock going to sit :excl:

Looks like I will have to make new mounting brackets for the calipers so they sit higher on the rotor, making room for the shock :38:
"There are a number of mechanical devices which increase sexual arousal, particularly in women. Chief among these is a Pumped Up Surf."

91 Hilux Surf, with a few extra's ....
SAS by http://www.budscustoms.com.au
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