Saab/Vectra Front Brake Upgrade

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Re: Saab/Vectra Front Brake Upgrade

Postby Doug » Sun 08.05.2011, 21:32

Steve, it's not necessary to remove the whole front clip to change out the brakes! :mrgreen:
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Re: Saab/Vectra Front Brake Upgrade

Postby racerstev » Mon 09.05.2011, 04:51

Doug wrote:Steve, it's not necessary to remove the whole front clip to change out the brakes! :mrgreen:



NOW you tell me! :wink:
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Re: Saab/Vectra Front Brake Upgrade

Postby Brit-Car-Nut » Mon 09.05.2011, 04:58

But it sure makes it easy to reach everything!
HD Replacement Shift Cables and Short Shift Kits still available
HD Replacement Shift Cable and Short-Shift Kit prices
Please contact me via eMail, not by PM
Download Manuals Here
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Re: Saab/Vectra Front Brake Upgrade

Postby racerstev » Mon 09.05.2011, 21:00

The real reason was I had to get to the oil filter... Got it all apart and STILL couldn't get to the
darn thing. So I dropped the engine, geez that was in November!

Hoping to get it running this week..

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Re: Saab/Vectra Front Brake Upgrade

Postby tigerdog » Tue 17.05.2011, 22:11

nitroman wrote:Dear Bob,

I've got a used cotter pin from one of the rear drums of a 1923 Templar roadster. I'm sure that I'm only slowing you down by mentioning that 1923 is the first year Templar started putting brakes on all four wheels, as by now I'll bet you've already come up with a great series of linkages for the Elan to modulate these mechanically-actuated, pre-hydraulic-era drum brakes.

When the conversion/installation package is ready mail it to me and I'll reciprocate with payment in kind, plus a little extra. Sorry to bore you with so trivial a task.

Cheers, Matt

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Re: Saab/Vectra Front Brake Upgrade

Postby nsr250 » Fri 20.05.2011, 18:57

Finally got around to installing this brake kit. DRAMATIC improvement in stopping !!! The brake pedal has a bit more travel and feels softer which is a bit strange but the braking power is great!! Really not any tougher to install than new rotors and pads. Drilling out the new rotors turned out to be no big deal and only took about 10 minutes. Thanks for all the effort put into this!!
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Re: Saab/Vectra Front Brake Upgrade

Postby djcar » Thu 14.06.2012, 18:30

tweetdriver63 wrote:I've just completed the upgrade of my front brakes using Bob Brown's help. He's the man with the plan. My upgrade used Saab 9-3 calipers and Subaru Legacy rotors.

Here's the parts list and where I got them:
From Rockauto:
2000 Saab 9-3 calipers, NASTRA Part # 8305455 Loaded; Set of 2; Reman Front Loaded Pair $154.79
2003 Subaru Legacy rotors, Raybestos Part# 980141R Professional Grade; Outside Diameter 11.545" / 5 Bolt Holes $29.79 (each)

Supplied by bobbrown:
4 15mm spacers for mounting calipers to hub
2 Hub-centric rings
4 bolts for mounting calipers (must be 15mm longer than the originals)

From local parts supplier:
2 12oz Prestone synthetic Dot4 brake fluid
1 tube of anti-seize compound (for caliper bolts)

Total cost (US dollars) approximately $250.00 (+ whatever bob asks for the bits he made for me)

The job is very straight-forward. I chose to got the easy route and got a pair of loaded calipers. Obviously, anyone doing this upgrade can get them unloaded or semi-loaded (whatever that means) and get different pads to their liking. Bob sent me a word document with some brief instructions, but once I started, I could have done without it. In fact, I took my laptop with me, but never actually looked at the instructions.

Here is the (sort of) step-by-step, in pictures:
These little dust covers hide the caliper mounting bolts. I just grabbed them with pliers and worked them off. (they won't be needed with the new calipers)
P9301343.JPG

Remove the two caliper mounting bolts with a 10mm allen wrench/socket.
P9301342.JPG

I swung the calipers up out of the way and rested them on that bar/control arm/whatever it is (see pic).
P9301344.JPG

The hubs needed some sanding to get rid of most of the rust, specially on the center part so that the little rings would go on. I used 150 grit paper. Once I had sanded enough to get the rings part way on, I used the new rotor to push them all the way back. Then I put a couple of the lugs into the rotor to hold it in place, although not tightened.
P9301345.JPG

P9301349.JPG

I had loaded calipers, so I mounted them all at once that way. Put some of the anti-seize commpound on the ends of the mounting bolt threads, then put them through the mounting holes on the caliper, the 15mm spacer, and mount those puppies. Torque the bolts to 70 ft/lb.
P9301347.JPG

P9301348.JPG

After everything was mounted and fit properly, I moved the brake hoses from the old calipers to the new ones. 11mm or 7/16" sockets both will work. Somehow I managed to forget to take a picture of the completed job before the wheels were back on. Sorry. Here's what you can see through the Fed 16" alloy:
P9301350.JPG



this looks doable for me... I'm in Canada look slike I can order these parts online how do I get parts from Bobbrown? Can we paint the calipers I wanted to get yellow ones as my Elan is green so they stand out and I have 17" rims... was hoping to get Hispec ones but can't find where to buy them....
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Re: Saab/Vectra Front Brake Upgrade

Postby Rice crispy » Thu 14.06.2012, 22:19

Look for bob on the forum and click on the envelope below his name and drop him an e-mail.

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Re: Saab/Vectra Front Brake Upgrade

Postby rip » Thu 14.06.2012, 23:59

djcar wrote:Can we paint the calipers I wanted to get yellow ones as my Elan is green so they stand out and I have 17" rims...

Yep. See the 6th post down on this thread. The red calipers are Vectra V6 ones (under 16" wheels).
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Re: Saab/Vectra Front Brake Upgrade

Postby djcar » Fri 15.06.2012, 23:31

great thanks...
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Re: Saab/Vectra Front Brake Upgrade

Postby superbad » Sun 12.08.2012, 23:07

Installed these today (finally). Pedal feels a bit soft, or maybe it's just the longer travel. I haven't bled the rears or fitted the stainless lines on that end, so there could be a bit there. Anyway, stopping is hugely improved. I was never able to lock the fronts with the stock brakes, and I have pretty strong legs. Now you can easily get it right up to the edge of locking, and modulate it on and off. In other words, it's exactly how it should have been from the beginning. Thanks yet again Bob.

Also, we have the drill template for the rotors here in Denver. I can't remember if I gave it to Randy or stuck it on the shelf, but it's here somewhere if someone else needs it.
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Re: Saab/Vectra Front Brake Upgrade

Postby tweetdriver63 » Mon 13.08.2012, 04:53

I just took the Subaru discs to a machine shop, and provided them one of the OEM discs to use as a template.
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Re: Saab/Vectra Front Brake Upgrade

Postby lotos » Fri 05.10.2012, 15:05

Thanks, Bob and everyone else! Finally got this kit on the car last night. Took about 2.5 hours as getting the old calipers off was a bit confusing to my mechanic at first, and the hub-centric rings were a bear to get on, but we did it gradually and they just made it. Had to whack on the metal bit that holds the brake cable half-way to make it hold the new stainless lines to our satisfaction, bending it ever so slightly. Did a bit of bedding-in but cars behind me kept from really doing it right so that's first order of business when the weather clears. Did a brake fluid flush and bled all four (but only put stainless on fronts so far), as others have said lots of travel, pedal isn't super firm, but I'm sure once I bed these pads in I'll love the change. And comparing the rotor size old and new is pretty comical. My only decision now is whether to bother keeping the old crap in case this becomes a Barrett-Jackson million dollar car down the road and people want it bone stock :lol: I'm leaning towards throwing the old stuff out.
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Re: Saab/Vectra Front Brake Upgrade

Postby steve matthews » Fri 05.10.2012, 20:41

Randy, watch those front brake cables. They move about and can rub if not positioned perfect.
Check them from time to time.
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Re: Saab/Vectra Front Brake Upgrade

Postby lotos » Tue 09.10.2012, 02:29

Thanks, I'll try to keep an eye on that.

I finally had a chance to bed in the pads, did a bunch of nice firm stops from 70-30 and by the end, I squealed them a bit and felt the fronts starting to lock up. Still lots of pedal travel as everyone else has mentioned, except now when I put my foot on it, the car slows quickly instead of ... well ... okay, we can stop. Very happy with the upgrade.
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Re: Saab/Vectra Front Brake Upgrade

Postby donsladek » Wed 21.11.2012, 04:18

Folks,

Does anyone have one of Bob Brown's kits for this conversion that they would be willing to sell or borrow to allow duplication? I've attempted to contact Mr. Brown numerous times to get a kit, but it appears he has gone silent on a number of projects.

I'd be willing to create drawings to share if I can get the parts - don't think there's anything exotic in the design...
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Re: Saab/Vectra Front Brake Upgrade

Postby juneaubehr » Fri 30.11.2012, 13:27

donsladek PM sent
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Re: Saab/Vectra Front Brake Upgrade

Postby ccb056 » Fri 30.11.2012, 22:57

donsladek wrote:Folks,

Does anyone have one of Bob Brown's kits for this conversion that they would be willing to sell or borrow to allow duplication? I've attempted to contact Mr. Brown numerous times to get a kit, but it appears he has gone silent on a number of projects.

I'd be willing to create drawings to share if I can get the parts - don't think there's anything exotic in the design...


I'd be interested in any drawings you can produce for Bob's parts.
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Re: Saab/Vectra Front Brake Upgrade

Postby superbad » Sat 27.04.2013, 23:23

Just measured these parts for another member. The attached zip file contains PDF and solidworks versions of the ring that reduces the ID of the rotor so it fits on the hub, and the spacer for the calipers. You will also need to redrill the rotors to the correct bolt spacing. There are a couple drill jigs floating around for this, or any competent machine shop can do it with an original rotor to use as reference.

In addition you will need the following hardware (McMaster-Carr part numbers included below):

2x Rotor Retainer
FHCS M6x1, 16mm long, stainless 92125A238

4x Caliper Bolt
SHCS M12x1.5, 55mm long (Odd pitch, not available at McMaster). 60mm long will work too, 55mm is hard to find.

4x Serrated Belleville Lock Washer 93501A033
Attachments
Lotus Elan Vectra Brake Parts.zip
(168.29 KiB) Downloaded 129 times
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Re: Saab/Vectra Front Brake Upgrade

Postby superbad » Wed 10.07.2013, 14:45

Just edited the caliper bolt- should actually be 1.5mm pitch, not 1.75.
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