C303 disc brake conversion

[ravio]

Ciao everyone, i have seen in several threads some nice pics of disc brake conversion for the Volvo portal axles...
I am working on these great axles since i got a pair of them.
i don' t like so much drums and mine were in such bad condition that while changing them, the disc option became a must.

I would like to understand something more about it as my ideas are quite confused.

Looking on internet i have found quite immediately http://www.omt-offroad.com/ in germany, for sure a beautifull kit but what a price !!!!!

Arska-tehtaalta suggested me these 2 finnish places:

http://www.offroadtarvike.fi/etusivu/

http://www.offivaruste.com/catalog/index.php

both seems to do disc conversion.

A friend of mine here just machined the wheel hub, made the 6 holes and runs on this way...someone here used 2 extra flanges on the inner and outer side of the reduced hub to have a flat surface where to insert the new scews...i think it' s smart ;)

Another guy i met on another forum machined the hub even smaller and welded a brand new biult 6 holes flange to it.... don' t know if it can become weaker in this way...

This is my first 4x4 and my first serious job! i am pretty sure i couldn' t find anything more complicated to do with my poor knowledge!:D
I' d just like to adopt the less invasive solution and do it in the best possible way...

I really like to have you opinion!

Ciao have a nice week end!!!

[pee]

Hello Ravio,

that way to do it, like offroadtarvike or offivaruste is most common and simple + cheap way to get fe. toyota discs suite for C30X axles

those two extra pieces are "hightech" in my eyes, but it doesnt mean that they are bad or useless

I think there is no need to weld any extras, main point is get those surfaces straight against discs, and if you make holes and "worms" for 6 x 139,7 circle, you have many variations for rims

there is some picture from my project, i used toyo discs, wilwood and rover brakecalibers

http://forums.offipalsta.com/showthread.php?t=37646&page=2

mr. pee

[offroadjouni]

Here's one topic from our ex-garage -> http://www.fjdc.org/bbs/viewtopic.php?t=373 . The Jeep is using Offivaruste disc brake kit.

[ravio]

so basically i can have the hubs machined here to the diameter of 173 mm , 6 new holes at a 139.7 mm and place new columns in those ones...do you have a straight hole or with a thread to screw columns in?
by looking at the link in ex garage forum in these 2 pictures it' s clear the process...

[ravio]

...it seems that there is a flange bolt on with the 2 extra screws...:confused:

i looked everywhere on offivarusta web site but i could not find any email !!!!!!!!!
do you know if they have one to email them for pricing?

Ciao enjoy your sunday!

[offroadjouni]

i looked everywhere on offivarusta web site but i could not find any email !!!!!!!!!
do you know if they have one to email them for pricing?koopee;)offivaruste.com

[ravio]

i' ll write them right now thank you!

[Pauli]

i' ll write them right now thank you!

Put your mobile number to the message, so KooPee can call you.

[pee]

do you have a straight hole or with a thread to screw columns in?
by looking at the link in ex garage forum in these 2 pictures it' s clear the process...


6 holes with thread, and hexagon bolts from inside

those 2 smaller holes with threads are for "centering" the disc - and in picture ther is spacer bolted... (not needed there)

[ravio]

thank you!
i ve just received an email back fro offivaruste they say they have a new bolt on kit for a disc conversion on going that will be available in 2 - 3 weeks...i' ll wait to see it before doing anything!
Does anyone of you know anything about it?

[Pauli]

Does anyone of you know anything about it?

Yes, I know that, but it's a product development, so I will not tell, sorry.

[Pete]

Yes, I know that, but it's a product development, so I will not tell, sorry.
This means that Pauli doesn't have a glue what is happening there (he works for offivaruste):D

[pee]

This means that Pauli doesn't have a glue what is happening there (he works for offivaruste):D


onks Paulilla liimat loppu :D

tarkoitaks Pete >clue> ??? Sorry, oli ihan pakko...

[Pete]

onks Paulilla liimat loppu :D

tarkoitaks Pete >clue> ??? Sorry, oli ihan pakko...
Heh:D

[liisi]

Does anyone of you know anything about it?

http://forums.offipalsta.com/picture.php?albumid=1135&pictureid=55924

[ravio]

here i am ! just finished sand blasting and priming every single part of the axles!
i think i' ll wait to see what' s this new product!
thanks pauli i am just curios about it!!!
can you eventually tell me if in the main time i can have the hubs machined and the new holes drilled for my 16 inch wheels? i suppose it's still needed.

i am trying also to calculate which inclination i need to give to the flat part where the leaf spring lies on on the axles looking at the original patrol axles...it seems to me something around 22 23 degrees fron and rear...

did anyone of you make something particular on volvo's to adapt them on the patrol?
Ciao have a nice day!

[LaaLaa]

have the hubs machined and the new holes drilled for my 16 inch wheels? i suppose it's still needed.

Hi ravio,
I have the 'feeling' that those new under construction disc brakes are supposed to fit regular 15" rims with original volvo bolt pattern:)

[ravio]

here some pics of the c303 as i founded it

[ravio]

another one and all axles dismounted sand blasted and primed.

[ravio]

i did not understand that the previous image was of the new kit...if it' s like this i think i cannot use my new 16 inch rims with standard nissan 6 holes... :(

[ravio]

hey guys do you know which toyota model' s discs are used for the conversion?

[Jeeper]

in this disc brake swap is KZJ rotors: http://forums.offipalsta.com/showthread.php?t=18738

[Patu925]

http://translate.google.fi/translate?hl=fi&sl=fi&tl=en&u=http%3A%2F%2Fwww.offroadtarvike.fi%2Findex.php%3 Fpage%3Dyrityksemme

There is one kind of version...

[ravio]

got it, i' ll go for them too...
in this pic from the thread you linked me to, it' s shown the custom built flange for the caliper screwed to the outher 7 bolts diameter of the gear box case, do you think that attaching it to the inner 6 bolts can be possible? i think i saw it somewhere done it in this other way...which solution will be easier?

[ravio]

if i am basically right what i should need to do is to machine my volvo whell hub to a 173 mm diameter, after that have the 6 new holes drilled in a 139,7 mm diameter....

looking on brembo website the drawing with all toyota disc measure, i just checked for my personal curiosity the nissan patrol datas, and i have noticed a couple of differences that caught my attention ( i hearbyt attach the 2 drawings as well as the list of all models using these rotors):

it seems that the nissan bolt pattern is 137 mm diameter???? i think it' s a mistake, did they maybe forget a "9" ?????
nissan holes are for M12 and toyota 14.55.... can i use my whell stud M12 x 1,25 or do i have to get new ones bigger?
At this point i am asking someone driving a toyota: is the wheel the same or does it have a different bolt patter/holes measure???

Thank you again !!!!

By the way checking on internet and asking a dealer here in my country i have found an afyter market rotor for that toyota disk made by DBA disc brake australia, with a slotted face that seems to be more performant! i think i' ll go for that !

ciaooo

[extremetoy]

see here..

http://pirate4x4.no/forum/showthread.php?t=8200&highlight=skivebrems+portaler

You can use googletranslate..

[ravio]

nice and easy job but i think i prefer to have it bolt on rather than welded !

[extremetoy]

nice and easy job but i think i prefer to have it bolt on rather than welded !
You dont trust your welding?? :D:D

[ravio]

definitely i don' t thust my welding capabilities !!!!!!

[ravio]

r u using volvos as well?

[extremetoy]

definitely i don' t thust my welding capabilities !!!!!!Sounds like you should bolt theme :)

[ravio]

that' s what i' ll try to do! i am finding quite a lot of good tips here ! u guys up there in northern europe know how to deal with these axles !
i was asking to swamber something about it as he has a patrol like mine, he told me that toyota disc should be machined down from its 319 mm outer diameter to 314....can you confirm it? is the wheel too little for that diameter?
next week i' ll get the discs, some cheap ones i was intentioned to get the dba series 4000 but i want first to use those to be sure they can fit in ....

i' ve seen also 2 ways of bolting the new "C" brackets to hold the brakes caliper, one in the inner six holes pattern that originally i think was holding the rear drum brake cover, and the other on the 7 holes of the gear box cover...what do you think it' s easier? personally i think the six one...even when it' s all assembled should be easier to remove it in case of need...

[ravio]

On the web i have found these codes for Wilwood calipers
#120-6816 front
#120-6811 rear

It seems they were the ones used by Portal tek when producing the disc conversion kit for Volvo axles: does anyone know if they are the same used by offivaruste or offroadtarvike?

Monday i' ll receive the discs and bring them with the hubs to have them machined...i' ll finally see something moving in the right direction !
Ciao have a nice week end !!!

[ravio]

hi guys how are you? i finally got a set of discs and the hubs are under the lathe for machining!!!!! hopefully in a couple of days they will be ready!!!!
any opinion about wilwood calipers?
a friend of mine running volvos with wilwood took them out for other brakes as he told me they were not braking :(
any opinion about them before buying?

he had these codes that i could not find anymore on wilwood web site (maybe an old model)
cu 120-5093
mt 120-5094 not sure which of the two in front and the other rear

these ones should have been the one used by portaltek when producing the conversion kit
portaltek
120-6816 front
120-6811 rear

and another guy i know uses 120-6815 both front and rear :confused:

don' t know which one to use ...

does anyone of you use any wilwood caliper? are they good ? is the braking action good even when offroading hard?

[Holst]

does anyone of you use any wilwood caliper? are they good ? is the braking action good even when offroading hard?

Hi!

Get calibers with piston dust seal, keeps your brakes in better shape longer time, specially if you use often your car in poor conditions.

We have made our disc conversion with LR D2 rear calibers and Toyota discs, works fine. And caliber fitting goes under 6 bolts...

Check from here... http://forums.offipalsta.com/showpost.php?p=663931&postcount=27

[ravio]

very nice!
hope to be soon ready to set up everything and run it too!
do you know anyone running wilwood calipers?
is this the toyota disc that you use?

[Holst]

Yeah i thinks it´s same but i use non vented. My friend have wilwood calibers but no dust seals..

very nice!
hope to be soon ready to set up everything and run it too!
do you know anyone running wilwood calipers?
is this the toyota disc that you use?

[Markus a]

Hi,


I will do the same operation on my portal axles so I'm a bit curious as to how it goes for you :)??

[ravio]

ciao Markus my project is going veeeeeeeeeery slow unfortunately !!!!!
i had some problem with my job, moved in another city so my free time was quite little!!!! anyway i am getting back on track in these days, i just saw the wheel hubs machined and with my surprise they have done a great job !
I' ll get them next week and i' ll post some pics.
i got the new columns from these guys http://www.distanziali.it/ te ones on the right side where it' s written "così lavoriamo noi" and the new holes have been done to match the inclined head of it and with threads inside
I got a pair of discs for the rear and i am pretty sure that i' ll get a pair of DBA for the front

[Markus a]

Nice... i will be waiting for som pictures :)

[1fzpower]

Any pics of your final conversion?