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The latest engineering mad idea
https://www.ausmini.com/forums/viewtopic.php?f=2&t=51575		 Page 1 of 2
Author:  david rosenthal [ Thu Mar 26, 2009 6:14 pm ]
Post subject:  The latest engineering mad idea
here is the lastest project. 4 piston alumin calipers with 8" ventilated rotors to fit inside 10"wheels.

The calipers are machined from 6062 T6 aircraft grade billet. The pistons are 1 1/2" dia and made from 304 stainless. The brake pads are DB208 and work out to just under 20% of the disc face area.

The calipers have duraflex steel inserts between the calipers to hold the pads. The steel inserts are a stiffener and stop the caliper flex, which is a big problem with most after market calipers.

The whole lot is fitted to a std drum hub with a alumin adapter plate. The track is increased by 20mm per side, so either spacer drums or extended axles with std drums would need to be fitted to rear.

I still have to have these finally checked by the engineer, but the constuction exceeds the maximum requirements for stess and tortional loads. Inital pressure test had only .005" deflection at 3000 PSI.

If you want a set of them just PM. They are not cheap but still a lot cheaper than a set of std cooper S discs. ["bling" :D at exra cost or see Gafmo, he loves polishing mini bits :lol: :lol: ]

Those blokes with machines to do a similar job I can give you pics and details of jigs and machining. Nothing hard ,just time consuming

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Author:  Fiji [ Thu Mar 26, 2009 6:18 pm ]
Post subject: 
so how much are they ... or do i have to pm for that ?
Author:  simon k [ Thu Mar 26, 2009 6:18 pm ]
Post subject: 
top stuff David - been waiting for these :D

which wheels did you test fit them with?

can you do a 'disassembly' picture showing the components?
Author:  Mick [ Thu Mar 26, 2009 6:53 pm ]
Post subject: 
:shock:

Jebus H!

You don't screw around david!

wow!
Author:  NAV [ Thu Mar 26, 2009 7:17 pm ]
Post subject: 
:shock: Umm..........Damn. That's stimulating my package :oops: :lol:
Hmm what do you accept for payment?? 8) :shock:
Author:  david rosenthal [ Thu Mar 26, 2009 7:20 pm ]
Post subject: 
Here is the pics of all the components. I tested them into a 10" contessa mag wheel, (The only mags i've got).
I haven't included a pic of the pistons still got to finish polishing them.
Piston seals are a standard item, I can give you the part number later if you want it.
These are all new parts, (Rotors, etc), all up cost of parts, material is over $600. To manufacture a pair ready to bolt on is well over 100hrs machining, fitting etc.
I know this isn't the right place but, price for a pair, (Customer supplies hubs, drive flanges and top and bottom ball joints).
Price $1400 (Ready to bolt on with new taper roller brgs)

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Author:  gafmo [ Thu Mar 26, 2009 7:30 pm ]
Post subject: 
Must admit I'd love to get a set of these in my hot little hands and give them a extra Bling and also see if they fit in Dunlop wheels also :wink:
Author:  Fiji [ Thu Mar 26, 2009 7:48 pm ]
Post subject: 
are these a one time thing or going to be made for the future also.
Author:  Blokeinamoke [ Thu Mar 26, 2009 7:51 pm ]
Post subject: 
That is really good work - they look the business. Well done 8)
Author:  Kennomini [ Thu Mar 26, 2009 8:59 pm ]
Post subject:  Re: The latest engineering mad idea
david rosenthal wrote:
The whole lot is fitted to a std drum hub with a alumin adapter plate. The track is increased by 20mm per side, so either spacer drums or extended axles with std drums would need to be fitted to rear.

I still have to have these finally checked by the engineer, but the constuction exceeds the maximum requirements for stess and tortional loads. Inital pressure test had only .005" deflection at 3000 PSI.


So we give you a pair of standard drum hubs and you can machine them to take these brakes?
The rotor, is that a standard mini item?
How much dose a set of standard S brakes increase the track of a mini?
Once your engineer checks them off can anyone bolt them straight on their road going mini and still be legal?
Sounds and looks like a good job and deal :) .
Author:  david rosenthal [ Thu Mar 26, 2009 10:03 pm ]
Post subject: 
I only fitted these to drum hubs as I did not have any cooper s hubs. I can machine the inner half to fit a cooper s hub with the bigger drive flange. The alumin can be cut to what ever size is required.
The track increase is 20mm wider than a std drum track. I think the cooper s track is 2" wider overall than a std drum track.

The rotors are off a diahatsu mira L200 [early 90's] and are also available in same size solid rotor. They are 8 3/16 " od standard ,so I machine them back to 8".

With ANY after market brake componets that are fitted to a road car the engineer's report only covers the item to ensure that it is going to be good enough for the application. Any car that has after market componets fitted MUST be inspected by relevant state transport authority to ensure that the braking system still works correctly.

The thing that I have done with the design of the calipers is to fit the steel blocks to stiffen the caliper halves to stop them spreading under pressure.
This idea of the 3 blocks has never been tried before as far as both the engineer and I know. The only after market brakes that use a single block bridge are Wilwood brakes that are made in America. They make brakes for various race and drag cars.
Author:  drmini in aust [ Fri Mar 27, 2009 6:32 am ]
Post subject: 
David, I have modified a bunch of Honda Civic brakes in the past to fit Mini drum hubs and drive flanges (10-12-13" wheels).
Drum (or similar 997/998 Cooper) drive flanges work OK on many road cars but I'm concerned about their use with big wheels, big or turbo motors, or track use. These flanges don't appear to be real strong.
Ivan Glasby from Mini Spares and Repairs told me that over the years he has seen many failures of Cooper drive flanges on the track, whereas the S ones are much stronger.
Ditto the S C/Vs.
Would it be worth standardising on S ones, as you don't know the use to which your brakes may be put?
My 2c,
:wink:
Author:  Tombo [ Fri Mar 27, 2009 7:06 am ]
Post subject: 
They look very nice 8) You're giving me ideas for my lathe. Was the only other engineering type tool used a drill press? or was there milling too? I don't have one of those :cry:
Author:  mickmini [ Fri Mar 27, 2009 7:24 am ]
Post subject: 
cool stuff David :D

Are the bleed nipples and brake hose inputs standard Mini threads?

Are the pistons made by you or are you using a commonly available one?

Never mind the seal part number - what are they out of?

Just the standard maintenance questions....

Oh and I am with kev re the flanges and cvs. Late model UK disc flange and cv would also work better than the old drum ones.

cheers
michael
Author:  mattsmadmini [ Fri Mar 27, 2009 7:44 am ]
Post subject: 
Sh1t hot as Usual David.... cant wait to see them in action...
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