How to upgrade to cossie brakes (Updated 27/07/2011)

[antony215]

Yeah but you should be able to get them from fords cheap Have a look on here shows you how and what you need http://www.rsbible.co.uk/

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[SafeChav]

Originally Posted by MorryRS

Cool exactly 4mm is it -milled i suppose -then fix the caliper on with a bolt and nut??

I bought mine as a set that had already been fitted to an Orion, i did measure up ages ago and i think i measured something like 3.7 or 4.7mm, 4mm should be fine though.

Anyway thats the easy part of the conversion. Place the caliper against the hub and you will see the holes are ever so slightly not in line, its a tiny amount but i did find when it was time to put the bolts in after tapping the M12 thread into the hubs the bolts were awkward to get in, i had to wind both bolts in together to start and then do up each bolt bit by bit, otherwise they tried to go in on the piss.

Then once you've done then you'll more then likely scream when you realise the brake pipe connection points out directly at the CV joint, you'll need some 90 degree adapters in order to fit pipes and clear the CV joint.

[SafeChav]

Just spotted you ask about bolts. Just go to your local fastening place and get some HIGH TENSILE M12 cap head bolts, i was advised the cap head bolts bolts over hex bolts, apparently stronger although i can't possibly comment myself.

[MorryRS]

Will check it at home - cant get into it at work , only get the front page

Cheers

[danskfocus]

Schmidi

Try here http://www.randbmotorsport.co.uk/sho...p?ProductID=49

[MorryRS]

Originally Posted by SafeChav

I bought mine as a set that had already been fitted to an Orion, i did measure up ages ago and i think i measured something like 3.7 or 4.7mm, 4mm should be fine though.

Anyway thats the easy part of the conversion. Place the caliper against the hub and you will see the holes are ever so slightly not in line, its a tiny amount but i did find when it was time to put the bolts in after tapping the M12 thread into the hubs the bolts were awkward to get in, i had to wind both bolts in together to start and then do up each bolt bit by bit, otherwise they tried to go in on the piss.

Then once you've done then you'll more then likely scream when you realise the brake pipe connection points out directly at the CV joint, you'll need some 90 degree adapters in order to fit pipes and clear the CV joint.

Cool that clarifys things up - i will take them into my work then and get the caliper machined and the hub taped to M12 . Yeah heard about the brake hoses , ordered some off Mike Rainbird

[mercury xr]

If I got Granada Scorpio Cosworth Callipers , do they use the same pads as a sierra cosworth, and escort or are they all slightly different?

[mentalasanything]

Guy's, just updated the thread to show a rear brake conversion, what you think??

Lee

[sexr3i]

Sound, but if you buy the oddkidd rear brackets you don't need to grind the corners off the bolts, they come with countersunk holes and bolts to fit em. But oddkidds kit needs slightly longer rear hoses, with the "mad for it" brackets you just use another front set of mk4 escort ones. With both mad for it and oddkidds you get all spacers etc required.

And the mk5 RS2000 handbrake cable definately fits proper. You just use the rear section up to the half moon. How come it took you so long? It's about 6 bolts each side. With a tea break and bleeding mine took about an hour a side.

How come you used solid disks too? Mine are vented all round.

Mercury - Same pads.

[mentalasanything]

Originally Posted by sexr3i

And the mk5 RS2000 handbrake cable definately fits proper. You just use the rear section up to the half moon.

Definately didn't fit mine, couldn't even get enough cable to come out to wrap aroud the handbrake arm on the caliper. I'd never seen one like it before, 2 cables and a half moon that the cables fitted into....

On the other hand, I bought an Escort Cossie handbrake cable today, a one piece jobbie which appears to be the one I was after, so we'll see when I fit it next weekend. It's identical to the RS Turbo one even has the adjusters on the one side near the half moon, except with ends to fit calipers.

Originally Posted by sexr3i

How come it took you so long? It's about 6 bolts each side. With a tea break and bleeding mine took about an hour a side.

It was a combination of not having the correct sized disks, waiting for new disks to arrive, not having spacers and waiting for my uncle to make them, when you count up the time spent on the car, it really didn't take too long, an hour and a half.

Originally Posted by sexr3i

How come you used solid disks too? Mine are vented all round.

Vented disks are off the Escos/Sapph cossie 4x4, the calipers you have must be off one of those, the calipers I have are off a 2wd Cosworth/XR4x4 hence solid disks.

[sexr3i]

The escort cossie sounds more like the one you should have been given in the first place, one cable that hooks round the half moon. Think the mk6 RS2000 ones are different, they may have given you that one?




Yeah I've got 4x4 cos calipers. Didn't know you had 2wd.

[mentalasanything]

Originally Posted by sexr3i

The escort cossie sounds more like the one you should have been given in the first place, one cable that hooks round the half moon. Think the mk6 RS2000 ones are different, they may have given you that one?




Yeah I've got 4x4 cos calipers. Didn't know you had 2wd.

That's the fella! Dont know what went wrong there then, perhaps it was for a mk6.

Yep 2wd calipers (Edited the guide to show now!), they're cheaper and more than adequate for my usage, the only reason I've upgraded is because the pistons were nackered on the drum setup.

Lee

[rsvmad1]

ort lads i just bought rear axle and leafs for my mk4 van and apparently all the hard work is done.(the hubs are off and plates welded on for calipers and the fitments are there for discs and wheels) i have pix but dont no how to ad them to messages. Apparently All i need is cossie 2wd discs and calipers.(and brake bias valve to stop it lockin up if wanted). Does any1 now if i need anything else. Also i need a pair of front lowerin springs(60mil) may buy struts aswell Cheers lads

[mattyred s2]

i did the rear brake coversion on mine earlier this year, i fiitted a 3 door cozzie handbrake cable on mine couldn't get the right mk5 rs2000 handbrake cable (think theres three different one's for the rs2000) local motor factor could only get hold of two types both wrong ones ...

[studabear]

has anyone got any links for getting the oddkidd rear conversion bracket kit, I'm about to start converting my turbo cabriolet, I've got my front 4x4 calipers and like the sound of the oddkidd kit mentioned earlier in this thread, I'm not keen on the idea of grinding the bolt heads back to clear the hubs

[StuRST]

Originally Posted by SafeChav

Just spotted you ask about bolts. Just go to your local fastening place and get some HIGH TENSILE M12 cap head bolts, i was advised the cap head bolts bolts over hex bolts, apparently stronger although i can't possibly comment myself.

what length do these need to be?

[rst1990]

good thread here mate used it for my rear disc conversion and it helped alot in sourceing the parts the only thing that you dont mention is that the rear disc reduces the lengh of the wheel bolt going into the wheel because the old drum is about 5mm thick but the rear disc is about half an inch thick so your reduceing the amount that the bolt goes in to the thread. thought i might mention this as after all they do hold your wheel on. i know that the bolt feels tight when its in but its not in the thread enough.

[rs shawn]

Did you buy new wheel bolts then? What length did you go to?

[mentalasanything]

I havent got standard wheelbolts so I didn't notice. I have the speedshack ones with the collars.

Lee

[rst1990]

Originally Posted by rs shawn

Did you buy new wheel bolts then? What length did you go to?

yer bought new wheel bolts from elites tyres and wheels cost a tenner i got the new wheel bolts half inch longer than the originals they also come collard.

[rs shawn]

1/2" longer.
Thanks, haven't done this myself but sure it will come in useful to others.

[escombi]

Does it matter if I use 253mm solid disks on the rear? or do I have to use 273mm? wot disks are the conversion plates made for

[ricky_2006]

can you put the standard s2 15" wheels on if uprated. coz i got sum 16" tsw 90's wheels on and want to change them bk to standard?

[mentalasanything]

Originally Posted by ricky_2006

can you put the standard s2 15" wheels on if uprated. coz i got sum 16" tsw 90's wheels on and want to change them bk to standard?

Yes, see the pics on the first page

Lee

[rs shawn]

First post mate...

[escombi]

does anyone no wot other calipers and carriers ae the same as 4x4 cossie front and 2wd rear thanks for any help

[kidsRS]

Is it the same process in fitting the cosworth 4 pots to the front of a s1 or 2?

[xrmalin]

Originally Posted by kidsRS

Is it the same process in fitting the cosworth 4 pots to the front of a s1 or 2?

Why dont you read the rest of the thread and you'll know its not. You need to have the calipers machined 4mm off the mounting face some thing like this


you can also see in the picture you need to modify your bake hose to a bolt and banjo instead of just screwing it in like like the ones on your car at the minute.
mark.

[martinmilne]

on mine i got the 2wd discs with std turbo callipers just need some brackets to fit the calliper after works very well much better than std discs and alot cheaper then buyin cossie callipers too

[Rs Adz]

briliant thread guys one question would anything change on this guide doing it on a base model mk3 instead of a turbo and if i do rear discs do i need a brake biase valve cheers

[xrmalin]

same process mate wether it be a turbo or not
bias valve theres alot of mixed views some say you need one some say you dont

[StephenC]

Which of these brackets would be best???
clicky
or
clicky

[B16CVH]

Originally Posted by StephenC

Which of these brackets would be best???
clicky
or
clicky

Ive got the bottom ones

[StephenC]

do you know if they suit 4x4 discs?

[xrmalin]

Originally Posted by StephenC

Which of these brackets would be best???
clicky
or
clicky

ive got the bottom ones aswell i think the brackets are the same wether you want to run solid disc's or vented like the 4x4 its just the calipers that are differant 2wd calipers for solid disc's 4x4 for vented disc's
mark.

[StephenC]

cheers gents

[trooper1991]

hi there can any one confirm which brake hose i need off a vw and which braided brake hoses i need also does any know the part number for the actual handbrake needed many thanks chris

[makaveli96]

Hi guys I have just collected every thing needed to do a cossie 4x4 rear brake disc conversion, here are some pictures and how much I’ve spent on parts.

Brand new genuine Cosworth 4x4 callipers £130
Brand new 20 groove vented CRN brake discs £70
Brand new EBC greenstuff pads £40
Brand new Conversion Brackets, Bolts and spacers £30
Brand new Goodridge braided rear brake pipe £32
Brand new mk5 RS2000 hand brake cables £28

Total £330

And at the front I have

Tarox G88 40 Grove ventilated standard size discs.
Standard size Cailpers painted in Gold & EBC Greenstuff Pads
Front Goodridge braided brake lines
ABS system removed

Picture of the fronts



And these are the cosworth 4x4 rear brakes












As I left the garage I used the brakes gently and straight away I can feel the differents at the back feels a lot more stronger than the rear brake shoes that I had removed, I’ve kind of almost used the brakes to it’s fullest and do have to say it brakes perfect and well balanced with the fronts with no locking up or brake noise what so ever, so the new rear standard ford compensator valves that I had fitted last year do work well and no need for upgrading to the bias valves or even upgrading to much bigger brakes at the front here’s a few pictures of them fitted I’m well pleased of them what a result.

[morph]

had problems fitting mine as the caliper carriers were toucking the outer edge of the discs and could not see why? are there slightly bigger disc available for the 2wd cossie? as i cant understand why these are touching only possiblity is that my discs are bigger than 283mm!

[morph]

Originally Posted by makaveli96

Hi guys I have just collected every thing needed to do a cossie 4x4 rear brake disc conversion, here are some pictures and how much I’ve spent on parts.

Brand new genuine Cosworth 4x4 callipers £130
Brand new 20 groove vented CRN brake discs £70
Brand new EBC greenstuff pads £40
Brand new Conversion Brackets, Bolts and spacers £30
Brand new Goodridge braided rear brake pipe £32
Brand new mk5 RS2000 hand brake cables £28

Total £330

And at the front I have

Tarox G88 40 Grove ventilated standard size discs.
Standard size Cailpers painted in Gold & EBC Greenstuff Pads
Front Goodridge braided brake lines
ABS system removed

As I left the garage I used the brakes gently and straight away I can feel the differents at the back feels a lot more stronger than the rear brake shoes that I had removed, I’ve kind of almost used the brakes to it’s fullest and do have to say it brakes perfect and well balanced with the fronts with no locking up or brake noise what so ever, so the new rear standard ford compensator valves that I had fitted last year do work well and no need for upgrading to the bias valves or even upgrading to much bigger brakes at the front here’s a few pictures of them fitted I’m well pleased of them what a result.

i dont understand how your car has not managed to lock up the rears as they are stronger brakes?