October 21, 2012

Brakes (the stiff Swedish regulations for converting cars)

In Sweden, if you want to convert a car newer than 1993 you have to change, not only the motor, but also the whole brake system or the steering system. This means a lot more work. I don't want to convert an older car. I want a relatively modern and safe car if I'm going to bring my family in it every day.
So, I will change the motor, the transmission and the brakes. I'll start with the brakes. I don't want the whole project to fail in the end just because it's impossible to change to other brakes on this specific car.
In order to get your converted car approved in Sweden there is an organisation called SFRO, Svenska Fordonsbyggarnas Riksorganisation, Swedish national organisation for vehicle builders. They will pre-approve the car before the vehicle inspection approves it. According to a person I have been in contact with there, I need to change the brakes to something with "different performance".
The A2 has front disc brakes and rear drum brakes so "different performace" in this case means fitting larger discs in the front and probably discs instead of drums in the rear.
The holders for the front brake calipers are an integral part of the wheel bearing housing and it is not possible  to fit a larger rotor. The holders limit the diameter of the rotor. So, this means I have to change the whole wheel bearing housing. Check out this exploded view. Nr 11 is the wheel bearing housing. See the "hooks" to the left that won't allow a larger rotor.
I hope I can find a wheel bearing housing from a VW Golf or something that can house the larger rotors. The next rotor size is 280mm.
The rear brakes do not have any "ears" to bolt the calipers onto. This means I will either have to fabricate an extra plate which bolts onto the axle with holes for the calipers or replace the a stub axle with one with "ears". This image above shhows what it looks like today.
This image below is a bolt on adapter plates for converting a VW Beetle from drums to discs.
Similar plates could be fabricated and bolted on between the rear axle (16) and the stub axle (3). another idea is to change the stub axle to one from a car with rear disc brakes with mouting holes for the break calipers. This would probably mean also changing the wheel hub and bearing. Have a look at the next image with a stub axle from a VW Golf III with rear disc brakes. Notice the mouting holes for the brake calipers in the botton of the image. The stub axle doesn't look at all the same as the one for the A2 so I guess it will involve changing a lot of other stuff as well.
Well, the search for the best solution for changing the brakes goes on...

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