Aveo Rear 286mm Brake Disc Conversion

Dear all,

I am in the progress of doing a rear brake conversion. Using 286mm rear brake disc and a single pot rear brake disc. I will post more pictures as the progress goes.

Basically, the ABS will not be affected, as I will be using back the drum brake cover (which is the outer piece which the brake shoe rub on). It consists of the center hub, 4 X 100 studs for the rims, bearing, and a ring gear which works with the magnetic ABS sensor. I will cut away the whole outer drum part, only leaving the center hub part to reduce weight and also I need the center part consisting of the ring gear for the ABS to work as per normal. I only need the center hub, the bearing, the ring gear and the 4 studs. I will also be changing the 4 studs to longer one to accomodate a 10mm spacer so that my wheels come flush with the wheel arch instead of hiding inside the arch.

The cutted hub (drum brake cover) looked like this. The ring gear is supposed to be inside the drum brake facing the center of the car. The 4 studs is facing outwards towards the rims. The studs are under the hub in the picture. So it cannot be seen. The wheel hub is actually standing on the 4 stud in the picture.

http://img504.imageshack.us/img504/1...brake07mj7.jpg

The left is the 286mm rear brake disc I am using. The right is the 245mm original aveo front brake disc.

http://img504.imageshack.us/img504/2...brake10cv7.jpg

This is our original rear brake bracket (thickness 8mm) which is welded onto the rear arms. Have to dig out this piece to replace with another piece which is longer to mount the brake caliper. The 4 holes are for the hub. The one extra big hole is for the ABS sensor which will go through this metal brake, go through the drum brake and sense the ring gear on the hub. If this piece is not removed or digged out, the ABS sensor is not long enough to reach the ring gear with an added bracket (thickness 8mm).

http://img145.imageshack.us/img145/7...brake01oi9.jpg

After its digged out.

http://img504.imageshack.us/img504/9...brake02jg6.jpg

http://img504.imageshack.us/img504/8...brake03dx6.jpg

Customised bracket. This is before trimming. After the mounting of caliper is confirm, this will be trimmed to be smaller piece.

http://img504.imageshack.us/img504/3...brake04ba1.jpg

When its put on. I do not intend to weld it like the original bracket. Most vehicle's bracket are not welded. The cutted hub is supposed to be slotted into this center stem, with the ring gear nearer to the bracket. The ABS sensor will sense the ring gear through the hole you see. The big hole is for sensor to pass through. The smaller hole is the ABS mounting or securing screw.

http://img145.imageshack.us/img145/2...brake05xl8.jpg

Original drum brake assembly which is supposed to sit on the original bracket. Look at the drum shoes after 90,000km and 4 years usage. Still have 1mm left thickness for the thinner side (right side). Quite lasting I would say.

http://img504.imageshack.us/img504/4...brake06ff1.jpg

Will post more tomorrow or the day after. Do check back if you are interested.

are you doing anything with the front? they do do more of the braking

Quote:

---

Originally Posted by AVE0SAM

are you doing anything with the front? they do do more of the braking

---

Yes. Using front 303mm with forged lightweight 6 pot caliper. The disc are 2 piece removable (from center hub) with ventilated holes and steel braided goodridge hose. Brand is vttr.

wow!! this is gonna be exciting!! i cant wait to see the outcome!! post pics!!

if u were in america, id hug u for doing this.









































im straight.

HUGS ARE BETTER THAN DRUGS!! THATS UNLESS OF COURSE YOU JUST SEVERED YOUR LEG!!

Hi

My handphone went out of battery, so was unable to take some pictures missing in the process. But anyway, the brake bracket and the ABS Hub is the most important part and I am glad I had snapped them to share with you guys/gals. What was missed was the piece of bracket with an additional 2 holes to mount the caliper and also the trimming of it to be smaller and lighter and more beautiful (hidden when view from under the car and outside the rim).

http://img82.imageshack.us/img82/471...rake111ff8.jpg

I went on to spray the center of the brake disc black also. As you can see, the brake caliper is only utilising part of the disc near the outer diameter, the center part was sprayed matt black.

http://img82.imageshack.us/img82/167...brake12li5.jpg

The caliper and blue vttr brake pad was sprayed bronze to match the color of my front caliper. But realised the color is not very nice. Might spray to another color next few days. But not yet decided what color. Any suggestion which color will look great?

http://img82.imageshack.us/img82/177...rake111jn4.jpg

The 286mm EG6 caliper + VTTR rear disc brake looks small in my 17 inch OZ rims.

http://img82.imageshack.us/img82/821...brake14ky8.jpg

Some pictures of my front brake. Its pretty straight forward. Just have a extension bracket to extend the caliper mounting out for bigger disc clearence to fit the 303 mm disc.

http://img82.imageshack.us/img82/621...ake0111ib1.jpg

http://img82.imageshack.us/img82/739...rakebyuuk4.jpg

http://img213.imageshack.us/img213/7...ake0111qo9.jpg

OMG!!! thats really incredible!! ok, whos gonna start making low cost rear disc brake conversion kits?

My rear brake kit cost me about $800US with reconditioned brake caliper, brake piston and o ring seal, new steel braided hose, new VTTR 286mm disc slotted disc, new VTTR brake pads, customised bracket. Is it cheap? Anyone interested? I may be able to ship out a few sets for plug and play application. Lol...

You only need to dig out that old piece of bracket. The new one ned not be welded. It can just hang there secured with the 4 nuts like mine. I will ship them out with the brackets ready with all the holes for direct use.

You also need to send your brake cover for machining. Cut off the outer part, leaving only the center like what I shown in the picture.

Then you are ready to enjoy the tremendous increase in breaking power.

The rear offset disc made of lightweight aluminium alloy. 10mm thick. Original silver in color. This is after sprayed black together with rear brake hub and disc center.

http://img516.imageshack.us/img516/1...brake11oh8.jpg

Rear brake without the wheel blocking the view.

http://img516.imageshack.us/img516/5...brake12jt6.jpg

With the spacer on

http://img156.imageshack.us/img156/5...brake13lb2.jpg

More images.

6 pot caliper made up of light weight titanium alloy. Even the brake pistons are lightweight.

http://img46.imageshack.us/img46/8198/image005vt0.jpg

550 degrees celcius brake pads.

http://img46.imageshack.us/img46/6356/vttr02pz7.jpg

http://img293.imageshack.us/img293/374/image003kz7.jpg

2 piece brake rotor. There are 4 X 100 pcd model available, but I didnt bother to wait for the stocks to arrive, so I just drilled 4 X 100 holes and its ready to be used immediately.

http://img46.imageshack.us/img46/2032/vttr01gm9.jpg

thats just too friggin nice and i'm really jealous!!

im going to be doing this to my car. do you have the measurements from the spindle bolts (as in where you made the bracket adapter) it would save me form making my car undriveable to get them. and i and to see if my idea will work (non ABS cars only) but it would be big disc brakes all around for @ $800 (less if you can get better sources of the calipers etc)

I didnt take any measurements. Sorry mate. But my set still have ABS unaffected. I did not forgo the ABS. I felt thats important, so I retained the ABS unaffected even after modification.

Quote:

---

Originally Posted by xiaogary

I didnt take any measurements. Sorry mate. But my set still have ABS unaffected. I did not forgo the ABS. I felt thats important, so I retained the ABS unaffected even after modification.

---

my car doesn't have ABS so if i develop this for myself i am not even able to try to keep it.

Quote:

---

Originally Posted by us2003

Greetings from Russia.
It is interesting to me, what firm brake disks.
And a principle of work of brake system after change, where the manual brake has got to?:)
If it is possible a technical language because there are difficulties of translation.

---

the original poster cut his drum to for a hub, and then made a spacer to how the spindle bolt up as an caliper carrier attachment.

beyond that i am unsure of what brake components he used. or if there is a drum ebrake on the rotor or if the caliper has the ebrake.

Quote:

---

Originally Posted by us2003

Where has connected a rope? It is possible for a photo?

---

thats the brake line, it would go into the caliper (possibly need an adapter)

he is asking about where the hand brake (ebrake) cable hooks up

i'd like to see this go into production. i'd convert the drums to disks.

So is it $800 for just the rear disk brake conversion? or does it also include big front brakes?

Quote:

---

Originally Posted by NYChevoo

i'd like to see this go into production. i'd convert the drums to disks.

---

I can send one to US if you want. If will not be very ex. But you might need a mechanic over there to get it installed. The most difficult part is to cut the drum brake into hub and taking out the piece of metal before putting on the piece of custom made piece of metal (caliper holder).

It should be in the region of $900US if you send your drum brake to me. Or $1000-1050 without the drum brake send to me as I have buy a spare set of drum brake. Steel braided hose will come together with this brake kit.

Quote:

---

Originally Posted by khan4rtist

So is it $800 for just the rear disk brake conversion? or does it also include big front brakes?

---

Big front brake kit alone should be $1600-1700US. Its pretty simple. Plug and play. No cutting, no welding...etc. 303mm, 6 pot brake. Comes with steel braided hose also 500 degree celcius brake pads.

Trust me, original brake is not sufficient. Once you have this brake, you will know what is braking power. I think original brake is too small for a heavy hatch like aveo.

damn, that car must stop very quickly now

Quote:

---

Originally Posted by thehunterooo

damn, that car must stop very quickly now

---

Yes. I would say It stop at 1/2 or 2/3 the distance required compared to before. Especially when you suddenly changed from accelerating to braking and it happens on a down slope.

Too much stopping power is not good, the tyres will give way also, unless you use very good tyres. Another hole in the pocket. And too powerful brake will easily jam the brake and cause the ABS to kick in unnecessarily. Needed some time to get use to. Brake is very sensitive, brake a bit can already, brake too much, it will lock it. Now already gotten used, so its good.

lol yeah, thank god I dont have ABS, I dont think ive ever had ABS :P

Quote:

---

Originally Posted by thehunterooo

lol yeah, thank god I dont have ABS, I dont think ive ever had ABS :P

---

I used to have abs...then I got lazy and drank a bunch of beer... no more abs for me. :mrgreen:

:lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll:

Im sorry to hear that

This is an awesome upgrade. I'll have to think about doing this.

very very nice...!! and I agree the brakes on the aveo are definitely insufficient, though I have found this is quite common in small/cheap cars.

hi there..will this mod not create problems of uneven brake bias? and does the 07 aveo hatch have an abs? i mean they sold the aveo really cheap here in the philippines so i don't think mine came with an ABS..will that affect the performance? i really want to do this..i use my car at the track once in a while so an increase in breaking power is welcome

i doubt it has abs, i dont have abs, you will stop quicker im sure, but i have no idea about the brake bias in this instance, i doubt you would notice

hi xiao..i just found rotors and calipers to use for my conversion..the problem is i don't know what the rear caliper adapter looks like.moreover im confused on where would i re-attach the handbrake cables after the conversion.do you have pictures of for the caliper mounts at the rear? .my plan is to also cut the original drum brake assembly like you did.how did you cut it?do you have before and after pics?.. i'll be using rotors and calipers from a corolla AE101 by the way ( i think it is originally from the front end) call me a cheapskate but i got it for a very cheap price =-) ...your help would be highly appreciated ..

Quote:

---

Originally Posted by Brai

hi xiao..i just found rotors and calipers to use for my conversion..the problem is i don't know what the rear caliper adapter looks like.moreover im confused on where would i re-attach the handbrake cables after the conversion.do you have pictures of for the caliper mounts at the rear? .my plan is to also cut the original drum brake assembly like you did.how did you cut it?do you have before and after pics?.. i'll be using rotors and calipers from a corolla AE101 by the way ( i think it is originally from the front end) call me a cheapskate but i got it for a very cheap price =-) ...your help would be highly appreciated ..

---

Did you get a response to this? I like the idea allot, there is virtually no cost just time if you have the means, untill you get the components.

So This how i see it:
1 Cut the drum portion from the hub
2 Remove the mounting plate that is welded to the backing plate
3 Fabricate new extended mounting plate, (to compensate for the caliper to be mounted)
4 Determine spacer thickness for free operation of Brake Disc (10mm thick for parts illustrated)
5 Install caliper mount (fabricated), hub, spacer, and brake disc, to confirm mounting hole location of the calipers.
6 Trim caliper mount and pretty it up
7 Install components.

Am I understanding right?

Note: in the research that I have done it is suggested to replace the proportioning valve to one for disc brakes or wheel lock up could occure.

no i dont think that master xiao replied to my query yet... but then any input would be helpful...do you have other pix from your research aside from what xiao posted? i really would like to do this...

i have a similar project going on right now. which will be strictly bolt on, and very affordable.

Quote:

---

Originally Posted by petrified.rabbit

i have a similar project going on right now. which will be strictly bolt on, and very affordable.

---

+1 for bolt on, I couldn't fabricate a dent. No way am I going to start cutting into vital components.

Quote:

---

Originally Posted by petrified.rabbit

i have a similar project going on right now. which will be strictly bolt on, and very affordable.

---

could you pls post some pics of the bracket my dear sir...or better yet please post pix of the projects..thanx

I only have a few cad templates, but the only thing you will use original to the car is the axle, and possibly/hopefully e brake cable.

so your still in the process of fabricating ur kit rabbit? wouldnt mind rear disks alot better than drums

yeah, i cant pull the car off the road long enough to finish it up.