Aveo Rear 286mm Brake Disc Conversion

[xiaogary]

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.



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



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).



After its digged out.





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



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.



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.



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

[Brai]

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

[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 ..

[CBaRmy]

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.

[Brai]

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...

[thehunterooo]

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

[petrified.rabbit]

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

[daug1502]

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.

[Brai]

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

[petrified.rabbit]

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.