Front Disc Brake Conversion For
The Mk2
By Alan & Sheree
The
following is a conversion worked out by Alan, Sheree and a friend of
theirs, for their Mkll which would suit anyone who is wanting to up
rate their brakes and keep it all Ford.
The
following set-up uses Mklll Zephyr front discs with Mkll Zephyr bearings to
match the standard Mkll stub. MklV Zephyr callipers are then used, however,
Alan has noticed there are two bore sizes for these in the calliper, so do make
sure to get 2 matching ones.
INSERTED
NOTE: Below are the plans of the brackets. Drawn up from measurements supplied
by Alan and Sheree (Do double check dimensions, as they can vary slightly from
car to car)
For
Accurate Professional looking Brackets consider having them Laser Cut from 10mm
Steel. There will usually be a company that can do this in most cities and
large towns (Check the Yellow Pages under Laser Cutting). I can supply a DXF
file for this purpose if required, as this will considerably reduce the cost of
Laser Cutting. Check measurements against the parts you have and let me know if
I need to fine tune the DXF file to suit.
Email me Steve (59-Z-MK2) Site
Manager.
Above
is the completed bracket. The holes with the bolts fitted are threaded half
inch (1/2UNF).
Above
is the Mklll disc fitted with Mkll bearings to the Mkll drum brake strut. This
keeps the 7/16th wheel studs to match the standard rear diff. (In
this picture, the disc is covered with an anti rust paint, as it will be a
while before it will see service.)
Here
is the bracket fitted to the strut. Use grade 8 fine thread bolts and when
using Nylok nuts, save them for the final fitting.
Here
is a mock up of the calliper, showing the fitment of the bracket. (Yes, the
calliper will be rebuilt to new standards before being put in use!)
Below,
the VH44 remote booster as fitted to Alan and Sheree’s Mkll. This is a good out
of the way place to mount it. The angle of the photo shows it much closer than
what it really is, to the alternator (non standard engine fitted
Alan
and Sheree can be contacted for any details regarding this modification at
Many
thanks to Alan and Sheree for sharing this modification with us and for
providing the photos and measurements.
Disclaimer:
The advice and guidelines given in these articles are given in good faith.
The owners and managers of the Galeforce Zephyr site will take no
responsibility for any injuries or loss sustained while carrying out the
described tasks and procedures or any consequences arising. Please read
the Safety First
Article