by dapinky » Tue 27.05.2025, 11:28
As far as I know, there is no "instruction set" for any complete solution. This is for various reasons, but the bottom line is that brakes are one of those things that need to be right.
As such, I believe that any of the above mentioned solutions work fine, but need to be considered and fettled by the fitter in each case - so they are only generally attempted by those who have a basic understanding and desire to get it done..... so it doesn't need a 'step-by-step' guide - a nod in the right direction should get a competent DIY mechanic into the right starting point, and it can be sorted from there.
For anyone else, I would say "go and buy the 'ready to fit' kit from PNM at their high price" - the price covers the research, development and liability costs which none of the "DIY" versions have.
That is my general disclaimer for "The massed public", but to try to guide you, I can offer the following:-
The solution using the Honda Civic callipers was designed by Jamie N, and I haven't heard any negative things about it.... but there is no 'simple' bracket design information available in general circulation..... it requires the bracket and a solution for the handbrake cables which he will either provide, or supply information on, as he wishes. (or you can DIY with the right skills).
This uses the 'standard' disc/hub units - or will work with the separate "Bob Brown" hubs/discs, or the Daewoo hub/discs, or the Astra hub/discs (as they all use the original fitting points).
The Daewoo hubs use the original upright spindles, so still have the separate bearings which will require the same maintenance as the Lotus parts
The Astra G hubs are 'sealed for life' units which require removal of the Lotus spindle and slight machining of the uprights to allow clearance for the unit to bolt to the original holes in the uprights - but will never need bearing maintenance during their life.
All of the above are a mix-and-match set of ideas - the Civic callipers are more modern than the OE ones, and are easy to get parts for in the UK and elsewhere.
OE callipers are good enough if they are correctly set up and then maintained - but if you don't want the hassle, then Civic ones could be considered to be "better".
Bear in mind that the rear brakes do not do a lot of actual work most of the time, so there is no need to go bigger....... but some people wish to do so, just for the aesthetics of the bigger units. Which needs consideration for whether the spare wheel will fit over them.
If your current rear brakes are not passing the MOT standard it could be either the calliper, the disc or the proportioning valve (if it's the hydraulic portion of the test), or the callipers/discs/pads mechanism if it is the cable-operation part of the test.
As for what is "best" - well, it is personal preference and belief!
On my car I have OE callipers (except they have been replaced with new Oldsmobile Cutlass Supreme units), BB hubs, Astra disks (Apec DSK117), Centric ceramic pads, original handbrake cables, and fully adjustable proportioning valves.
On Angies car I have the same brakes, but the hubs are the Astra G sealed units, with Astra G discs.
However, before I found that there is still a reasonable supply of new callipers for £25 each at Rock Auto, I was all set to use the Honda Civic system, with the Astra G hubs/discs and have to do something with the cable system.
If and when the GM callipers become impossible to source (the rebuild parts are few and far between - well, the pistons are obsolete now anyway) that is the way I will go - but for now, the OE callipers, with good pads and adjustable prop valves seems the "best" for me. (even though there is some fettling to do to one side handbrake lever - but once done, it will then fit any other new GM calliper in the future).
I am yet to find anyone with a negative to say about the Civic system, and the PNM system seems to be developed to a state where it is now fit for purpose at the rear, whilst some people say that the GM system is "old design" and tends to be maintenance heavy. Certainly, the supply of OE rear pads in the UK is limited, but if you shop in USA they are plentiful, at a ridiculously cheap price (but can get dear when you add in the shipping/handling if that is all you are needing at the time).
The Astra G hubs and discs are cheapish and easily available in the UK (at the moment), and Honda calliper parts and pads are still easy to get - and likely to be for a good time due to the numbers of cars still using them on the UK roads.
All of the options are 'reversible' anyway should the need ever arise.
I know that SWL now have a supply of new OE disc/hub units which are machined correctly (unlike the ones I got from SJ's) should that be something that you wish to consider.
Dave
Just the one now, but this one's mine! - and it will be finished eventually..... - but also temporary custodian of a project until it is finished enough for Angie to drive it
...oh, and a 2006 Freelander destined for the jungles of The Gambia - 4500 miles across roads, desert and tracks - what could possibly go wrong?
