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

[makaveli96]

I was thinking the same too morph but for some reason it brakes perfect with no lock up with hard braking I think it's all down to how well balanced you can set the brakes up and plus the rear brakes are hardly that much stronger than the fronts only slightly by the way I did have them fitted by Jamsport who do know what there doing.

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[morph]

Originally Posted by makaveli96

I was thinking the same too morph but for some reason it brakes perfect with no lock up with hard braking I think it's all down to how well balanced you can set the brakes up and plus the rear brakes are hardly that much stronger than the fronts only slightly by the way I did have them fitted by Jamsport who do know what there doing.

yes i think its because the small calipers on a rear disc conversion bite quicker therefore lock the wheels as you have gone for the 4x4 calipers they are the same size as the fronts therefor use the same amount of hydraulic pressure through the brakes lines as the front.
good setup! all you need now is a bigger master cylinder.

[rs_dude]

http://cgi.ebay.co.uk/Ford-Escort-RS-Turbo-Cosworth-4-Four-Pot-brakes-big-283_W0QQitemZ230409588986QQcmdZViewItemQQptZUK_Car sParts_Vehicles_CarParts_SM?hash=item35a57b50fa

READY TO FIT!!!

[Red_bull]

Are the calipers of a Ford Scorpio Cosworth the same as the sierra 4x4 for the front of a ERST?

[botters]

will the 2wd 4 pots fit with standard wheels?

[xrmalin]

Ive finally got round to getting my cossie 4 pots on my estate this weekend ive not tried them out yet because the cars not on the road yet but they look so much better.
Firstly i got my calipers off b19 cvh off here (cheers pal) with the right hoses to fit straight onto my car. After reading up on the conversion i got a friend to machine the required 4mm off the mounting face so they looked like this





after getting the discs from a local motor factors i offered everything up and the disc sat smack bang in the middle of the caliper so let the drilling comence.
The standard calipers use an m10 mounting bolt where as the cosworth stuff uses m12 so i drilled the hubs out and tapped them m12



now the mounting holes in the hubs are slightly out of line to the holes in the calipers so i opened the holes out in the calipers from 12mm to 13mm and this gave me plenty of room to line them up and get the bolts in.
Now with the calipers all bolted up



dont they just look so much better that the standard jobbies and even better still my wheels still go over them so i dont have to change to alloys



hope this helps some one out if there planing on doing the same thing once ive got the car on the road ill do a little update on how they perform

cheers for reading mark.

[luxembourgrst]

hy i have front 4x4 calipers and 4x4 discs i need to put 20.2 mm spacer between the bolt and i c an t fit the standard 15 rs trubo wheels on i need to buy me 2wd discs an fix it with 1mm spacer that i can again put my 15 standard rs turbo wheels on

[dingla rs]

im thinking fiting 2.0 ltr focus rear brakes on rs turbo my friend doing ,pretty sure i can make them fit mabe rs 2000 cable will fit 2 i hope

[turbo_king69]

im about to do the cossie rear brake conversion on my s1. already got cross grooved + drilled front disks. will let you know how it went in about a weeks time....hopefully....

[stiff1]

years ago rear wheel drive fords had nuts and front wheel drive had bolts. i think this was just way they did things

[kristinthomas21]

Can't get my pads to fit for some reason, Also, but I thought I was grinding on the caliper bracket but finding it hard for them to spin freely.







scrap car

[eoeumc]

Sorry if I have missed the answer to my question, but had a quick look and didn't see anything apart from:

Originally Posted by SafeChav

rs shawn not having a locating hole isn't a safety aspect as jarnok is saying, its merely there as you say to make the wheel easy to fit without the hub spinning and causing the alignment problems.

The reason they don't have it........is because the brakes we use are all from cars with wheel studs pressed into the hubs

[quote=mentalasanything;2291977]No, the original master cylinder can cope fine.
quote]

But my question is can I change my master cylinder (with or without changing servo) to a cosworth one and get away with having more fluid pushed through to help with stopping power on a standard brake set up?
Now baring in mind I have a converted Cabriolet with as far as I know standard brakes.

btw, a great thread peeps

[Red_bull]

Is there anyone that knows the ford number to order a handbrakecable for the rear brakes with discs?

Thanks in forward

[jsXR3I]

hey ppl im having some trouble trying to find the right handbrake cable. My cars a S1 RS Turbo and im trying to put cossie 4x4 calipers and disc's on the back but ive try'd the rs2000 cable but the sleeving is to short so i tryd a cossie one but it look like its exactly the same but with a longer inner cable. plz help. thanks!!!

[sham27]

i did this conversion using everything you said about 12months ago and the wheel wouldnt go round i had 2 get my 283 disc machined down 2 278 the same size as a 4x4 disc.....then they worked fine....has any1 come across with this problem

[sham27]

Originally Posted by jsXR3I

hey ppl im having some trouble trying to find the right handbrake cable. My cars a S1 RS Turbo and im trying to put cossie 4x4 calipers and disc's on the back but ive try'd the rs2000 cable but the sleeving is to short so i tryd a cossie one but it look like its exactly the same but with a longer inner cable. plz help. thanks!!!

i done this conversion 2 my old s2 and i used a rs200 cable....and it worked fine....by any chance have you put the mountin bracket on the right way if i remember right the caliper should look like its on the top of the disc not 2 the right or the left....hope this is some help

[mentalasanything]

Originally Posted by sham27

i did this conversion using everything you said about 12months ago and the wheel wouldnt go round i had 2 get my 283 disc machined down 2 278 the same size as a 4x4 disc.....then they worked fine....has any1 come across with this problem

That's odd, my 283mm disks fitted fine. Were you using cossie 4 pots by any chance?

Lee

[Red_bull]

Is the BC2290 from burton the right handbrake cable to order for this conversion?

https://www.burtonpower.com/product_...px?CCode=PC090

[tasos77]

Originally Posted by Red_bull

Is the BC2290 from burton the right handbrake cable to order for this conversion?

https://www.burtonpower.com/product_...px?CCode=PC090

make a search on ebay, try ''rs turbo rear'' as key word. The seller should be still there, i've bought mine for 20 GBP 6-7 months ago

[jsXR3I]

if you call burtons and say your doing the rs turbo rear disc conversion they will give you the right handbrake cable coz thats what i did after trying about 4 different cables

[s24bigbhp]

Hi there i just read through the top of your step by step on the rear conversion do I still need to connect my brake compensators back up (load sensors) or do I leave em off any help please?

[studabear]

Leave them fitted, make sure they are working.

Unless you are fitting the inline type or a bias valve.

[s24bigbhp]

They came off me e reg series two they bolt onto the wishbones what's that type sorry all new to this if I don't know I ask lol I also got cossie brakes on the front running a twenty five master cylinder is that cylinder ok aswell cheeRS

[mcbernie]

What hand brake cable do u use for the front part, the one that goes from the lever to the join?

[W40ERS]

right prob i am having is pedal is crap, cossie brakes all round and i have fitted mk5 servo and new master cyl (25.4), with restrictors then to rs turbo restrictors for the rear but rear brakes still lock up rapid. Do i have to remove both restrictors n fit bias valves instead for this set up to work right?? my lines r set up FR+RL And FL+RR off the master cyl. what has every1 else done? cheers

[wedge07]

hi ive done this conversion and now for some reason my tires have started to rub on my arches?? does anyone else have this problem?

[mentalasanything]

Originally Posted by wedge07

hi ive done this conversion and now for some reason my tires have started to rub on my arches?? does anyone else have this problem?

Hi there, is it the rears that are rubbing? What size wheels? I guess this could be down to the fact that they may sit a few mm further out than with the old drums.

Lee

[Antti O]

Does my standard front brake line fit to cosworth 4x4 front caliber directly?

[Cal Jones]

If I already have braided hoses for the escort calipers...will theese fit the cossie brakes?

[mentalasanything]

Originally Posted by Cal Jones

If I already have braided hoses for the escort calipers...will theese fit the cossie brakes?

For the front, yes. The rears are too short.

Lee

[YOREVOL]

just a quick note, when fitting 2wd calipers fit the hose to the inner bleed nipple hole, and the nipple to the hose hole. you wont need the 90 degree uion to avoid the cv joint.
i did it this way but loads of clearance issues so going to use bmw brembos and focus discs.
btw what are a pair of 2wd callipers machined to fit rst worth?

[Antti O]

I think you really cant do this conversion right.
I have now 4x4 front calibers, 2wd discs. In rear 4x4 cosworth full brakes and wilwood bias valve between rear brake line. Still rear brakes lock first and front brakes are horrible and dont have power.
Next option will be different master cylinder or selling this car, this is now 3rd summer fighting with brakes.

[mentalasanything]

I've done this conversion again over the weekend so I've now updated it a little and added the part number for the correct handbrake cable!

First Line Parts FKB1340 for Ford Escort 92>95 with rear disks excluding 4x4.

Also this time I countersunk the rear caliper adaptors and used countersunk bolts, much neater!

Originally Posted by Antti O

I think you really cant do this conversion right.
I have now 4x4 front calibers, 2wd discs. In rear 4x4 cosworth full brakes and wilwood bias valve between rear brake line. Still rear brakes lock first and front brakes are horrible and dont have power.
Next option will be different master cylinder or selling this car, this is now 3rd summer fighting with brakes.

Antti,

I've done this conversion again, this time on an XR3i (Non ABS with the 4 output master cylinder) and without a bias valve. They work fantastically now, better than they did on the RST. No lock ups and breaks evenly as it should. Handbrake holds well too. What M/C are you using?

Lee

[mentalasanything]

Just a quick update to add info about the Goodridge Banjo bolts supplied with the rear hose kit. They were too long and leaked. I had to shorten them by about 2mm to stop them bottoming out.

Lee

[bomsch]

Has anyone tried fit a Volvo 240 calipers? The are 4 pot and lot cheaper then "cosworth" ones. Fitted on mk1 Escorts as upgrade.

[simonmcf]

hi guys, little confused after reading the whole thread, quick question will the set up below work on my s2

front setup

2 cosworth 2wd calipers

2 cosworth new discs ( not sure if the 4x4 or 2wd)?

set of ds2500 pads

What price would ya put on it?

cheers
Simon

[xrmalin]

I used 2wd disc's with 2wd calipers when i did the the conversion on my old mk4 estate. Price is hard to say depending on where you get everything from

[ranzrs]

i know some1 has asked the question about the master cyclinder, and some says it fine but i was thinkin how can it be fine?

as the pressure from the cosworth system will be much great than the rs turbo system, so if your not changing the master cyclinder your not getting the full use of the cosworth brakes?

i dont know if im right or not, i just want to know as im planning to convert my braking system, so just want to know as i want to buy all the parts once

also is there a difference in changing 2 or 4 pots or isit the same?

also the pictures shown are they of 4 or 2 pot brakes?

and finally do 4 pots fit under standard rs turbo alloys?

[luke19790_3]

yes they fit under the std alloys^

st170 disc and mk3 mondeo caliper is also a good setup, should be cheaper to.

[ranzrs]

v6 mondeo calipers???

also is that just for the front??????

as i want to do front and back

also whats about the master cyclinder?