F***en Discs

[mezzmo]

Just had my discs sent back from the rod shop for the second time. Those of you that read my first post will remember that the back of the discs were rubbing on the bolt heads. NOW - they have supposedly been machined down to clear the heads, which they do - but now the back of the disc seems to hit the adaptor / caliper holding plate "SHIT". Am i doing something wrong here (entirely possible) for the record i have:

Attached the adaptor / Caliper plate on correctly
I have then put the large bearing onto the disc (to test)
I then slid the disc to the stub axle and seated onto the bearing
i then put the smaller bearing into the disc
This leaves an area of flat surface on the stub (about 10mm)
I then put the washer on with the cove to the inside
The washer with the tongue is too large to fit into the disc opening so i didnt put it on (again - just testing)
I have put the nut back on and tightened and the disc swims like a bastard on the stub axle

Its kind of like i need a spacer on the stub axle before i put on the large bearing

HELP PLEASE- this is pissing me off!!!!

[Rogue Trooper]

Uhhh, didn't we clear up last time that there shouldn't be any bolt head rubbing as the bolts are pushed through from the rear? The mounting plate holes are supposed to be threaded so there is no requirement for the original nylock nuts. That's why they specify all mounting bolts must be used with spring washers.

Mountings should look like this. Note the bolt heads...

The bolts go through in the opposite direction to how they were with the drums mounted.

[mezzmo]

Hey Rogue,

I remember your post from before but the guys seemed adamant that this was right. Did you get yours from Castlemaine Rod Shop? As a last resort i am going to remove the whole set up like you have a send it to them to do. One other question - how did you remove the upper and lower ball joints? mine seem stuck Fast!!

Even if i had the bolts coming through from the back, the back of the disc is still rubbing on the caliper plate - did you have any issues here?

Mezz

[mezzmo]

One other question Rogue, did you have to grind out the caliper body at all to clear the bolt head? Geez i wish you had more pics - sure would answer a lot of questions.

Cheers mate - thanks for the help

[Warren]

Mezzmo

Pictures would help even if they are crapy ones from a phone.

Warren

[Rogue Trooper]

I actually got my kit secondhand but it is definitely a CRS kit.

I'm sorry but whoever you were talking to has his head up his arse. As you can see mine are all mounted up fine. Sounds like whoever ground the rear bearing mounting in the rear of the disc has taken out too much meat so the disc sits too far back now. There is not a lot of clearance between the bracket and a brand new disc when it's all put together so if too much has been ground out then it could quite easily be rubbing.

With the bottom ball joint I unbolted the lower shock mounting first then partially undid the bottom ball joint nut and gave it a couple of whacks with a small club hammer and the spring did the rest. Undid the nut all the way and the bottom just fell apart nicely.

I then put some wood just below the hub assembly to catch it before it hit the ground. Then undid the top nut and gave it another couple of whacks and the weight of the hub assembly did the rest.

You shouldn't have to grind the caliper body, just the mounting bracket of the caliper itself. if you compare your caliper with the top picture I posted that should show you where.

Did you not follow the link I posted in your last thread? There were photos for Africa there.

[westy12]

gday mezz my caliper rubs on my disk too, i got brand new disks and on one side on the inside it has rubbed bad on the caliper and scratched it up good. i had to grind the caliper away but it still rubs a bit around corners!! the disks are on right and the calipers too... it doesnt do it on the other side!! go figure??

[Bas NZ]

Gee, my Beddie was built new with discs, well before (reg) with discs, thank god!!!!!!!!!!!

[Rogue Trooper]

Gee, my Beddie was built new with discs, well before (reg) with discs, thank god!!!!!!!!!!!

What are you talking about Bas, you're missing out on all the fun!!! 

[MaTTe]

To revive an old thread, mezzmo did you ever come up with the solution to this issue.

Among my various modification paths I have made a discovery of which im not sure if common or rare.
I had my disc brake setup on my machined stubs for MANY years before my time, and have recently obtained the bearings to make use of the smaller stubs without any modifications. However when it came time to fitting the rotors they kept fouling on the caliper adapter.

I made the mistake of thinking it must have been a minor tolerance issue so continued grinding the adapter wherever it was marked (painted the adapter, bolted up the rotor, spun it, ground the shiny section)
This continued for quite a while.

Turns out that the machined stubs are different to the other 3 sets. out of the 8 stubs I have here and all the ones I can find photos of on this site, only 1 set seem to be like this. the spacing between the bolt face is 8mm +/- before the step to the seal, where as the other 6 stubs only have a 4mm +/- spacing.
This may well have been your issue mezzmo.

I'll post this in more detail soon with details of my current disc brake conversion information photos and all.
My new conversion will be made to suit the 4mm spacing, however i would be interested to know how many people have the 8mm spacing on their stubs.