I was speaking to Dax the other day about upgrading the front brakes to use the larger diameter cosworth disks( sierra uprights ). Dax will sell you an adapter plate and the disks but will charge you £90 plus vat for the privallage. A bit costly me thinks so i contacted brakes international and have ordered the cossy disks and pads for £70 inclusive.

I have therefore to make up the brackets myself as dax want to charge me £50 just for the brackets alone.

The picture below is of said brackets supplied by A fellow dax builder David Thompson. I understand that they are made of 6mm steel plate. Has anyone had any expeirence of making these things?

Any input is most welcome

http://www.brakepart.co.uk/enterflash.html

If you can get the dimensions and have a drill man enough to go through 6mm plate i don't see why it should be tricky to do yourself?

Ned.

So, you're hiding out down here then

Chcuk me the dimensions (draw around them? Pixtures and sizes?) And my tame local laser profiler can knock them up for a few quid each...

Dave 'Dax' Graham :-)

Hi Dave

Well im not as advanced as a laser cutter yet, but chain drill , file and grind i can stretch to. I think finding the dimensions will be a bit easier when i have the new disks.
Im still short of the dimensions and if your offering to make them up your a very kind man... a very kind man.
I think it will be fairly easy to work out the dimensions as i know the diameter of the old disks and the new, so working out how far out the caliper has to move should give me the hole centres.
Cheers again

Julian Brewer
Cumbria

[Edited on 8/3/04 by Julian B]

Indeed

Has Dave T sent you those adapter plates? I can get them made up nae bother if you like...

<thud>

I can be so blonde at times you know...

He sent you a picture! Argh! Right, upright hole centres we know, caliper hole centres we know, all we need to know is how far to space them out from the original position. Shouldn't be too hard with a bit of maths.

Think I'll look into this in the next couple of days

Posting at the same time! Probably ought to take this over to the list...

Actually, I think I know the answer already. You have mail!

Your very kind to offer

Dont worry about making them up as a one off for me.Im sure i could bash some up in an hour or two.

Thanks for the offer again.

If however you can get your hands on the dimensions i would be very greatful.

Cheers

Naw, sod that. I could use a set myself. I'm sure a few other folk would be interested too, thus covering any costs involved

got ya..... back in sync now!

Well, I did try to post a message to the list, but as usual, NTL has its head between its legs right now...

I think I might have cracked it. If it's as simple as I think it is, then we're talkin 19mm? Problem is, really need to get a set of uprights with discs,as I doubt it's that simple

Hi

I have just had a quick look in the instruction book and i come up with 19mm as well. They do say that there is one mill clearence so i guess that makes 20mm then.

I will have go at a mdf template just to see if it all fits.

cheers

Julian,

I was worrying about whether the caliper mounting lugs were in the same place on the uprights on the cossie hubs and the normal Sierra ones, as this may make the dimensions change somewhat...

Ehh, I don't know if the question still remains, but yes; the holes in Sierra uprights and (2wd) Cossie uprights are the same. (at least in position radially).

The holes in the uprights are in the same radial position but you cannot mount the cossie (2wd, 4pot) calipers on the normal sierra upright. I've tried! The normal sierra caliper carrier is threaded, and the upright plain, but with the cossie, the upright is threaded and the caliper plain. You can tap out the standard upright beacause the holes are 10mm and the bolts for the cossie calipers are 12mm so the holes will tap out but then you have to bolt the caliper to the wrong side of the upright "ears", which puts the offset wrong, and that side of the "ears" on the upright is not milled flat. Even if they were, the offset would be wrong for the cossie disc, and also the tapped out upright "ears" look decidedly spindly and thin comapared to cossie ones.

You really need...2wd, 3 door cossie uprights (the ones that take the "normal" "taper with a nut on top" type bottom balljoint instead of the "pinchbolt type" fitted to the sapphire cossies, cossie 2wd 4pot calipers and cossie 2wd 285mm discs, then it will all go together.

I used this system on my RWD Peugeot 205 rally car, and tried fitting the cossie calipers and discs to the std sierra uprights and it doesn't work!! In the end I went to the full cossie setup.

Just read a bit more up the thread, those spacers are a damn sight thicker than 6mm!! If you use 6mm the caliper will flap about like a sheet in the breeze. Absolute min would be 8mm (I used this on a rear axle conversion once, but the calipers still flapped)

best would be 10mm mild steel.

The DAX plates are made up of 2 plates welded together to make the desired thickness. They can be used with Sierra calipers if a small part of the pad carrier is cut away to change the radius from that of the original to the increased diameter of the cossie disk.

The price has gone up a bit as they charged me £12 for a set of plates with all bolts etc!

Has anyone succeeded at making those adapterplates themselves?!?!

I'm looking for a way to use bigger discs in combination with my Sierra uprights and calipers.....

I've just helped fit a set of Sierra disks and calipers to a Moggy Thousand woody and the two adaptor plates on that were 3mm thick with a spacer between them and they pull it up no trouble.It's a really neat bit of kit but it cost £300+.