Neon disc swap how to - Page 3 - Suspension and Brake Forum

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Re: Neon disc swap how to
Friday, August 12, 2005 7:44 AM
come on whitecavy.. make it work baby...

Re: Neon disc swap how to
Saturday, August 13, 2005 8:39 AM
hotbug1776 wrote:

So you are saying that the center hole is just opened up, and is still centered on the bracket (compared to the original hole), and the four other holes are then added in at a precise location (determined by the J-body axle). What we are really locating off of is the center hole then. Am I getting this right?


Yes. As long as the center hole is centered, the rotor will be centered in relation to where it would be on the Neon. I hope that doesn't sound too confusing.

hotbug1776 wrote:

The four other holes are set so that the caliper is riding "level" to the ground (the same distance from the ground on both sides), correct?


I think I understand what you're asking. You're asking if the two horizontal centerlines (the top hole and the bottom holes) need to be parallel to the ground right? No. Not necessarily. Mine were actually a bit off since the part of the bracket casting where the park brake cable sticks out would have hit the top of the bearing flange on the axle. He did the center hole, then set the brakcet on the axle where it would clear the top of the flange, and marked the four holes. As long as the center hole is centered, you can rotate the bracket in any direction however far you want and the rotor will still be centered.

hotbug1776 wrote:

So, when doing this, I may have to do the center hole to the J's specs, then position the mount on my axle so it's set "level" to get my other hole locations.


Yup. When was looking at Whitecavys car at the Bash, the top of the bearing flange looks to be in roughly the same position relative to the axle as on my car. I had to do a tiny bit of grinding on the top of the flange to get the center holes to line up, but it wasn't too much.

I hope that explains it a little better. I will be pulling it all apart this afternoon or tomorrow, and I will take some more pics with some dimensions and some details of where the holes go.




Re: Neon disc swap how to
Monday, August 15, 2005 8:47 AM
You're the greatest :thumbsup:





Re: Neon disc swap how to
Thursday, August 18, 2005 4:01 PM
.....and the thread goes bump, Bump, BUMP!

I'll PayPal $20 USD for someone to finish this on a 3rd gen and write it up (with dimensions)

Jay




Re: Neon disc swap how to
Friday, August 19, 2005 1:38 AM
I just need the parts...my machining is done free at work (I work at a machine shop LOL). I'm trying to get a line on the stuff needed for the swap. just no time to call right now due to working 70 hours this week LOL.
If someone can get me the dimensions, I could have it done the day I get the caliper mounts. a little longer if I have to figure it out my self.

with all the info I've collected from this post I should be able to get the swap done fairly easily. this is what customizing is all about, doing the job for your car and letting others share in the idea and trying it on their own.





Re: Neon disc swap how to
Friday, August 19, 2005 2:49 AM
Aside from needing a brake line adapter still, I should have atleast one side on tommorow ebrakeless for the moment but once I make sure everything else is working well ill worry about the ebrake.





208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Friday, August 19, 2005 7:25 AM
I still need to find the stupid brackets.. The donor car I was working on is no longer in the yard.









~2014 New Z under the knife, same heart different body~
______________________
WHITECAVY no more
2012 numbers - 4SPD AUTOMATIC!!
328 HP
306 TQ
Re: Neon disc swap how to
Friday, August 19, 2005 8:38 AM
/me listens along with dave



Re: Neon disc swap how to
Friday, August 19, 2005 3:02 PM
I installed one side today, When my digital camera comes home Ill take a picture its all the hardware installed not pretty and cleaned up yet but just to prove it'll work fine on 3rd gens.

I didnt take the brackets to a machine shop because my turbos taking up all my funds so the brakes are going at extremely low budget but with careful measuring 6-7 times then drill with a drill press and god only knows how much dremeling everythings lined up good pads sit in the right location on the rotor. I figured I had a line on a second set of brackets just in case.

the top of the axle side of things took a good bit more grinding then i hoped, I actually took about a little over an 1/8in off the top with my sawsall.

Brake lines arent hooked up yet because I still need the adapter, for my first shot im going to see if I can make the stock line work with a thread adapter if not Im just going to use the rubber lines from the Neon which will also need a thread adapter.

As far as the ebrake goes it looks possible that the stock ebrake cable could work but I dont know Im not worrying about it to much right now cause ebrakes not a huge priority if the stock cable wont work.

And the BEST PART?

all this ready to go for:

$10 brackets calipers and neon lines (junk yard)
$36 Pair of rotors from napa
$23 rear pads pair from napa
______________________________________
$69

The adapters for the brake lines shouldnt cost more then 10 bucks.

rear discs for under $100


If you have any questions for me feel free to post em here or email me.



208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Friday, August 19, 2005 4:08 PM
sooo aahh when does your camera come home?

I more of a visually oriented kinda a guy.





Re: Neon disc swap how to
Friday, August 19, 2005 6:54 PM
Ok heres the Pic, like I said its coming back off for prettying up





If it didnt show up just look in my cars reg

Ill post mroe pics of my bracket and such when I take it back apart for cleaning and such and Ill take a picture of what I ground off my axle I may have ground a bit more then I needed there though no biggie its still strong.

Also just for reference all my parts were from a 96 neon



208whp 239wtq
13.7 @ 102mph 2.19 60'

Re: Neon disc swap how to
Saturday, August 20, 2005 12:14 PM
Alright!

What did you end up using to space the rotor away from the bearing?

I wasn't sure if the top of the 3rd gen axle would clear. Mine needed about that much taken off too. Right now I've got the car in the garage and I'm going to draw up a bolt pattern diagram with dimensions while I have it apart. I'm also going to weigh the discs versus the drums to see which is lighter, and take some more measurments as far as hub clearance, spacer thickness, etc. I'll post it all tomorrow.




Re: Neon disc swap how to
Saturday, August 20, 2005 1:00 PM
just curious as what your reason for spacing it out was? did it rub on something? I havnt messed with it much yet since Ive just been working on getting the other side on which it is, but the rotor spins free.

Is it something simple i just havnt noticed yet that is the reason it needs spaced?


Whats best about it so far is I can just use the stock lines if I can find a thread adapter to go from the J line to the Neon caliper size. worse comes to worse Ive got the neon lines



208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Saturday, August 20, 2005 5:33 PM
Just an update, I got the adapters for the J lines on today, waiting on brake fluid to fill err back up and bleed, hopefully everythings jolly from there then everythings coming back off for prettyin up then re-assembling



208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Saturday, August 20, 2005 7:02 PM
The rotor hits the backing plate/dust shield by maybe .010" or less when the wheel is torqued down. Its just enough to drag. You won't see/hear/smell/feel it until you get the car on the road. I drove it around the driveway with no issues, when I got it out on the road, it smelled/felt like the park brake was dragging.

Now that I've thought about it some more, I think you should try it first to see if it drags. I had everything powdercoated, so it may just have been the coating that was too thick (pictures tomorrow). I never got a chance to measure the overall distance from the inside of the bracket to the outer face of the bearing with either setup. If anything, it can't be more than .020 or .030 difference.




Re: Neon disc swap how to
Saturday, August 20, 2005 7:10 PM
im not using the dust shield and from your pics I didnt think you were either or are you talking about something on the J side of things and not that Neon dust guard? either way Ill take a closer look and see if its gonna be a problem, like i said i may jsut driv eit once to find out too. I would think jsut some washers would work though what did you end up using?




208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Saturday, August 20, 2005 9:13 PM
I put it together with the brand new pads cleaned upt he calipers and such and the only issue Im running into is my new pads are really thick seems like if i need to space the rotor for anything itll be that. maybe I missed something though, heading back out to mess with it



208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Saturday, August 20, 2005 11:03 PM
please get back to us


<a href="http://www.liquidgeneration.com" target="_blank"><img src="http://www.liquidgeneration.com/quiz/images/bat_freeze.jpg" border="0"></a>
Re: Neon disc swap how to
Saturday, August 20, 2005 11:34 PM
everything hooked up now i had to put a couple washers on each caliper botl because they wanted to thread to far and push the botom pad against the rotor the washers seem to have solved the problems itll spin pretty free now i really slight rub but its just the pads im fairly confident that one trip down the road and back with a few hard stops will get rid of that issue. If not its not that big a deal to pop the wheel back off an investigate further.

All thats left to do now is bleed and test might be a few days before I can road test it as ive got my exhaust all tore apart for my turbo related stuff but im sure i can hook the down pipe and manifold up and spin down the road once in a day or so Ill update again when Ive done that. till then ill just be answering questions or whatever



208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Sunday, August 21, 2005 12:38 AM
Ive got the pictures of everything cleaned up too btw if someone can host em only room in my profile for the 1 lol



208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Sunday, August 21, 2005 6:36 AM
How are you not using the dust shield? It doubles as the backing plate for the park brake setup..... I ended up cutting mine to a smaller diameter just for appearance.

I will gladly host the pics for you. Email them to me- james.w.cahill@us.army.mil, just try to keep them smaller than 250mb.





Re: Neon disc swap how to
Sunday, August 21, 2005 1:16 PM
Well like I said I dont have anything ebrake related hooked up so when putting it all together I guess I didnt notice I needed it for the Ebrake, none the less Ill just put it on when I get ready to dive into making the Ebrake work. Ill email you those picture too




208whp 239wtq
13.7 @ 102mph 2.19 60'
Re: Neon disc swap how to
Sunday, August 21, 2005 3:47 PM
This sounds very promising, once I get some time I'll attempt this for sure.

Can't wait to see the pictures.
Good luck on getting everything to run smooth.
Re: Neon disc swap how to
Sunday, August 21, 2005 5:17 PM
NotsoOceansideEco wrote:

Well like I said I dont have anything ebrake related hooked up so when putting it all together I guess I didnt notice I needed it for the Ebrake, none the less Ill just put it on when I get ready to dive into making the Ebrake work. Ill email you those picture too


Ahhhh. Makes sense now. Thats why you have no rubbing, since there is nothing there to rub against. When you do install the ebrake stuff, you will need to install it, since it works similar to a drum brake backing plate.

Here are some dimensions for the machine work/drilling (I did these with my trusty digital calipers, and they are just rough dimensions to +/- .001", but as long as the center hole is good, the other holes can be filed to fit) (sorry about the blurriness, I'm not too swift with PS, and I had to call my tech support person just to get this far)-

These are the dimensions for the holes-


And for the milling/grinding (the horizontal dimensions are centered on the center hole, the vertical is .270" above the top of the center hole, sorry I forgot to put that one in)-


In this picture, you can see the washers I used to space the rotor out, as well as my cut down dust shield/backing plate and where the rotor was rubbing-


Also- the Cav hub sticks out .250" through the rotor without the spacers installed. It sticks out .160" with them in, but that dimension can change depending on what you do for spacing.




Re: Neon disc swap how to
Sunday, August 21, 2005 6:24 PM
Here are NotsoOceansideEco's pics-

Grinding needed on the top of the axle-


Bracket after drilling/grinding-


Bracket/caliper/rotor mounted-





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