rear disk conversioon on my gsi??? - Corsa Sport - for Vauxhall and Opel Corsa B, Corsa C and Corsa D

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c0r5a756

Member

Registered: 15th Apr 02
Location: stoke-on-trent
User status: Offline

12th Nov 04 at 19:57

what do i need for this could do with a list of all the parts i will need as im going doo it next week end need some help any useful links etc

corsaandy

Member

Registered: 29th Jan 03
Location: Northamptonshire
User status: Offline

12th Nov 04 at 22:55

there is a tutorial for it on mig so search on there

Matty L

Member

Registered: 10th Aug 04
Location: cheshire
User status: Offline

12th Nov 04 at 22:56

quote:
Originally posted by c0r5a756
what do i need for this could do with a list of all the parts i will need as im going doo it next week end need some help any useful links etc

do you like your gsi?

Member

Registered: 10th Sep 03
User status: Offline

12th Nov 04 at 22:57

Rear Disk Conversion:

You will need-

Cavalier spacer stub axles - Non GSi/Turbo
Cavalier stub axle spacer plates - Non GSi/Turbo
Cavalier rear disks - non GSi/Turbo
Cavalier rear calipers
Castle nuts
Handbrake mechanism for rear hubs
Early Nova short handbrake cable

Removing Corsa Drum Set Up -

Loosen wheels.
Jack Car Up.
Set car down on axle stands.
Removehadbrake cable from the rear sub frame, as well as any fuel lines that are clipped to it.
Loosen the nuts that afix the rear suspension struts to the car.
Lower the subrame to the floor or onto some blocks of wood.
Remove the bolts that hold the rear subframe to the car.
Remove the rear sub frame.
Take off the grease caps from the rear drum.
Remove the castle nuts and pull the drums off.
Remove the four bolts that hold the stub axles to the sub frame and pull the stub axles off.
Grind the welds down the side of the spacer plates but don't take any material off of the sub frame then remove the spacer plate - you may need a cold chissle to whack 'em off, depending on how good a job you do with the grinder, but make sure you leave a flat surface on the subframe.

Fitting the brakes -

Align the spacer plates to thesub frame, you will find that at least one of the bolt holes should be in the same place. I'd recomend you weld over the un used holes and flatten the surface down before you continue.
Making sure the spacer plates are in the right place and weld the down the verticle sides to the subframe - a Mig welder will make easy work of this. Were not building ships here, just make sure they are on securely though.
Drill the new holes through the subframe using the holes on the spacer plate as a guide.
Bolt the stub axles to the sub frame.
Attatch the disks to the sub frame using fresh grease on the needle bearings and tighten the castle nuts.
Attatch the calipers to the mounting bracket.
Re-fit the subframe to the car.
Attatch the brake hoses.
Attatch the Nova handbrake cable.
Bleed the brakes though.
Re-fit the wheels and lower the car to the floor.

Cybermonkey

Member

Registered: 22nd Sep 02
Location: Sydney, Australia
User status: Offline

12th Nov 04 at 22:58

quote:
Originally posted by Matty Lee18

quote:
Originally posted by c0r5a756
what do i need for this could do with a list of all the parts i will need as im going doo it next week end need some help any useful links etc

do you like your gsi?

lol he wont like the look of the rear end when it catches up with the front on a wet day