I could'nt get the pictures i wanted in this post as they would'nt resize and photoshop runs really slow on my laptop,so heres some direct links to some bits i've been modding.I had a couple of spare days and this is what i acheived.
Firstly is a standard pedal box which started out in a bit of a state.
http://i170.photobucket.com/albums/u265 ... 97-1-1.jpg
http://i170.photobucket.com/albums/u265 ... 090092.jpg
http://i170.photobucket.com/albums/u265 ... 090100.jpg
http://i170.photobucket.com/albums/u265 ... 090099.jpg
http://i170.photobucket.com/albums/u265 ... 090098.jpg

So i got busy with the welder, die grinder and the sandblaster.
http://i170.photobucket.com/albums/u265 ... 240043.jpg
http://i170.photobucket.com/albums/u265 ... 240044.jpg
http://i170.photobucket.com/albums/u265 ... 240045.jpg
http://i170.photobucket.com/albums/u265 ... 240046.jpg
http://i170.photobucket.com/albums/u265 ... 240048.jpg
http://i170.photobucket.com/albums/u265 ... 240050.jpg

And ended up with a dashboard adjustable bias pedal box.
http://i170.photobucket.com/albums/u265 ... 090084.jpg
http://i170.photobucket.com/albums/u265 ... 090085.jpg
http://i170.photobucket.com/albums/u265 ... 090087.jpg
http://i170.photobucket.com/albums/u265 ... 090088.jpg
http://i170.photobucket.com/albums/u265 ... 090090.jpg

I've been working on these for a while now but finally i now have a pair of stenghtened 2 1/4" adjustable front suspension legs with 247mm vented discs and single circuit volvo 240 4pot calipers.
http://i170.photobucket.com/albums/u265 ... 090113.jpg
http://i170.photobucket.com/albums/u265 ... 090110.jpg
http://i170.photobucket.com/albums/u265 ... 090108.jpg
http://i170.photobucket.com/albums/u265 ... 090107.jpg
http://i170.photobucket.com/albums/u265 ... 090105.jpg
http://i170.photobucket.com/albums/u265 ... 090101.jpg
http://i170.photobucket.com/albums/u265 ... 090114.jpg

Cheers for looking.

Very nice work there!

Lovely job

Cheers for the compliments. I need to work out a new throttle pedal setup as the balance bar is in the way of the existing one.Not too much of a headache there though i don't think.....Fingers crossed!
At the moment the discs have a two piece spacer behind the hub to move the disc in,to centralise it in the caliper.In the next few days i'll be making a 1 piece alloy adaptor to relpace the wheel spacers and then get some drilled and groved discs and they'll be ready to fit.

This is awesome

More info on the caliper set-up please Like, everything haha i've been looking at 240 calipers for a while, as they should fit under 13's and be much better brakes? Do they just bolt on to the 300 hubs? What car are the disks from? and could we please have some extra pictures of these spacers please? Glad someones done it already, saves me all the trouble haha Thanks, Thomas.....................

Its not quite a bolt on affair as neither the calipers or the strut have threads cut into them in their original form but the centres of the holes in both line up exactly which made things alot simpler.Easiest way was to drill out the strut holes and tap a thread into them to accept an M14x1.5 bolt,45mm length.Then drill out the caliper holes so the bolts can go through.I think you can just about make out the thread on the strut holes in one of the photos.Finding the correct discs was the most difficult.Took hours of going through the Ferrodo brake book to work it out, but mk 3 capri 2.8 discs seem to be ok.Bit of over hang on the pads but only about a milimetre.Might try a slightly larger discs on the next pair i do.Once the diameter of the disc is worked out it needs to be spaced away from the hub so it runs in the centre of the caliper.I used wheel spacers to work out the clearances initially and have ordered some alloy bar 5" diameter and 20mm long that needs to be drilled out and a centre machined out so the hub fits snug into it.Also its up to you, but i converted the 4 pots to single circuit rather than dual circuit.In my opinion its much neater than dual pipes or T-pieces all over the place and its suprisingly easy to do.Once the struts are completely finished i'll do a step by step breakdown with photos,measurments and sizes of everything and exactly what was done and whats needed.Theres a bit of machining involved so be prepared to spend a little money.But its not complicated stuff.
Cheers.

clitti wrote:Once the struts are completely finished i'll do a step by step breakdown with measurments and sizes of exactly what was done and whats needed.Theres a bit of machining involved so be prepared to spend a little money.But its not complicated stuff.
Cheers.

Sweet! I look forward to it Thomas........................

P.S - Do we know if these will fit under 13inch wheels?

Hang 5,i'll check now.

13" standard steelies will need at least 20mm spacer.14" Leos will need about 5mm spacer.Thats just approximates though.I fitted 65 mm subaru wheel studs so theres plenty of room for spacers.

Ah ok, i've got 8x13 et+6 so will need to do some math and see what i get You say you used capri disks? did you have to re-drill them to the 300 bolt pattern? i've just looked and the brake disc bolt pattern isnt 4x100 is it, its around 85mm? Is that right? Thomas.................

Thats right.The centre bore of the disc needs to be taken out a touch too. 0.3mm iirc.Redrilling the disc is quite easy.Place the disc over the hub so the ford holes line up with the bolt holes that you bolt the discs on to the hub with.Turn it 90 degrees.Spray a bit of primer through the holes.Take it off the hub after its dried.Centre punch the paint marks and pilot drill the holes.Start small and work the size up to 10.5 mm drill size.Thats if you want to fit the discs directly to the hub.You can do this and run standard calipers but you will need to mod the caliper and carrier to suit the wider disc.I won't be fitting the disc directly to the hub so the measurements will differ slightly with the spacer placed behind the hub.

properly good work there fella them brakes are gunna put a 300 on its nose
keep at it

clitti wrote:Thats right.The centre bore of the disc needs to be taken out a touch too. 0.3mm iirc.Redrilling the disc is quite easy.Place the disc over the hub so the ford holes line up with the bolt holes that you bolt the discs on to the hub with.Turn it 90 degrees.Spray a bit of primer through the holes.Take it off the hub after its dried.Centre punch the paint marks and pilot drill the holes.Start small and work the size up to 10.5 mm drill size.Thats if you want to fit the discs directly to the hub.You can do this and run standard calipers but you will need to mod the caliper and carrier to suit the wider disc.I won't be fitting the disc directly to the hub so the measurements will differ slightly with the spacer placed behind the hub.

So did you re-drill the actual hub, or the disc? If you have to space the disk anyway, to save future disc drilling could you make the spacer a conversion spacer like you do with wheels pcd, is there any reason this wouldnt work?

Will you be at VOC this year?

Thomas.................

I left the hub original and redrilled the discs.When the disc was fitted directly.But now i have the spacer i could bolt that to the hub and then bolt the spacer to the hub.See what the engineers shop says about it. Spacers came today btw:D
Before picture.


For size perspective,they are sitting on a 12" floor tile.
After picture will be at the end of the week probably.