Restoration diary / 15-01-2006

15-01-2006 >> 10" conversion with Fiesta calipers and more on brackets for inter cooler/oil cooler

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15-01-2006 - Converting to 10" wheels with disk brakes normally is quite expensive. There is a cheap but experimental route, with Ford Fiesta calipers. The easiest way is with calipers from a Mk1 Fiesta, Mk2 has also been done, these are from a 1998 Mk4 Fiesta 1.3i, non-ABS with solid disks. I could get them for a small price, they've done about 8km, but have seen some water. On this photo from the left to the right: Original 8.4" disk caliper (for 12" wheels), my modified Fiesta caliper and the original Fiesta caliper. The green marks indicate where I removed material.
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15-01-2006 - Here you can see how much I had to remove to get this caliper to get enough clearance between the wheel and the caliper.
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15-01-2006 - Difference in height between the original and Fiesta caliper.
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15-01-2006 - Had to remove a bit on the inside of the solid mounted part of the caliper.
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15-01-2006 - This is the flange of a Metro. Normally it has lips sticking out to center the wheel. As they're in the way for the Mini wheel, I had them removed.
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15-01-2006 - The Mini caliper mounts on the other (under) side. The other side is flattened, but this one isn't. With the grinder I tried to get it flat. The (normally threaded) holes were bored out. The mounting holes in the Fiesta caliper are 1 or 2 mm more apart. Boring 11 mm is enough to get everything to fit.
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15-01-2006 - Fiesta caliper and normal Mini disk mounted. The disk is still too big in diameter.
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15-01-2006 - A view from the side. The caliper itself can glide freely in its rubber from left to right.
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15-01-2006 - Disk removed, wheel fitted. You can see the clearance.
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15-01-2006 - Here you can see how much the caliper sticks out of the wheel.
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15-01-2006 - Another view...
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15-01-2006 - Finished the brackets for the inter cooler, made room for the oil cooler and started work on its brackets.
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15-01-2006 - Close up of the second bracket for the inter cooler. I think it's strong enough, but will do some tests later on.
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15-01-2006 - The beginning of the brackets for the oil cooler.