Author Topic: Brake Upgrade - \'82 282 Volvo - 5.0L  (Read 14448 times)

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« on: July 19, 2012, 01:23:36 PM »

Michael Yount

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Brake Upgrade - \'82 282 Volvo - 5.0L
« on: July 19, 2012, 01:23:36 PM »
Some pics of the brake upgrade I\'m working on for the Volvo.  Here\'s a shot comparing some options.  Smallest rotor is the factory setup on the stock car.  A great system actually - 4 piston calipers up front/2piston in the rear - 10.25\" x .86\" vented rotors in front.  Lots of SCCA ITB guys have run these brakes on naturally aspirated cars with no problems - but you go through rotors and if top speed were higher there\'d be heat sink problems.  So I thought I\'d see if I could add some more capacity to deal with thermal load.  Here are pics of the stock rotor (10.25\"x.86\"), a 740/940 Turbo rotor (11.25\" x .86\") and a 2002 C70 Volvo rotor (12.00\" x 1.00\").  I\'m going with the largest.  Pics show the differences.

'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #1 on: July 19, 2012, 01:25:50 PM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #1 on: July 19, 2012, 01:25:50 PM »
I\'ll be using a 4 piston AL billet caliper by Wilwood - Dynapro.  About 6 lbs. lighter than the cast steel caliper on the car and slightly smaller.  Randal already showed a picture of what it will look like mocked up behind the wheel in the wheel thread on the car.  Here\'s one without the wheel in the way.

'82 Volvo 242; '10 Cayman S; '15 Fit

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«Reply #2 on: July 19, 2012, 01:36:01 PM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #2 on: July 19, 2012, 01:36:01 PM »
The challenge is that the caliper is a radial mount caliper; the car has two tabs on the strut.  So I have to make an adapter to fit the caliper to the strut.  After lots of careful measuring I mocked one up in pine -- just for test fits and confirming dimensions.









While making these changes -- I replaced the stock Volvo studs with 3\" studs -- you\'ll see those in this next shot with the caliper/rotor mocked up. (on the other side of the car)



Got some buddies that took my adapter drawing and wood mockup and produced this CAD rendering for me.  They\'re off to the machine shop to have a first try produced on a 5-axis machine.  Can\'t wait!!

'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #3 on: July 24, 2012, 08:58:05 AM »

02JEEPX

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #3 on: July 24, 2012, 08:58:05 AM »
That is gonna be sweet when you get done!
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«Reply #4 on: August 28, 2012, 09:21:37 AM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #4 on: August 28, 2012, 09:21:37 AM »
Should get the adapters from the machine shop this week.....
'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #5 on: August 28, 2012, 11:33:14 AM »

02JEEPX

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #5 on: August 28, 2012, 11:33:14 AM »
Cool! Can\'t wait to see them.
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«Reply #6 on: August 28, 2012, 09:06:05 PM »

CommunistWookie

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #6 on: August 28, 2012, 09:06:05 PM »
Quote from: \"02JEEPX\" post=1250
Cool! Can\'t wait to see them.

Likewise looks good so far

«Reply #7 on: August 31, 2012, 10:45:58 AM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #7 on: August 31, 2012, 10:45:58 AM »
More progress....!!!!!

'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #8 on: August 31, 2012, 11:37:07 AM »

02JEEPX

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #8 on: August 31, 2012, 11:37:07 AM »
Have you tested them yet?
RANDAL REGAN
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«Reply #9 on: August 31, 2012, 01:57:25 PM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #9 on: August 31, 2012, 01:57:25 PM »
Kaitlin\'s wedding trip Sat/Sun; just picked them up this morning.  Maybe test fit on Monday....here\'s a better picture...

'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #10 on: September 03, 2012, 06:54:29 PM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #10 on: September 03, 2012, 06:54:29 PM »
Passed the first test - dimensionally perfect bolt-up to the caliper.



'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #11 on: September 04, 2012, 04:26:05 PM »

02JEEPX

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #11 on: September 04, 2012, 04:26:05 PM »
See the last post on the page for latest update....

http://forums.turbobricks.com/showthread.php?t=260864&page=3
RANDAL REGAN
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«Reply #12 on: September 04, 2012, 04:29:46 PM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #12 on: September 04, 2012, 04:29:46 PM »
Thx Randall - I was going to post the same thing here - but you beat me to it!!!!!
'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #13 on: September 06, 2012, 07:04:33 PM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #13 on: September 06, 2012, 07:04:33 PM »
'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #14 on: September 07, 2012, 04:13:48 PM »

Michael Yount

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Re: Brake Upgrade - \'82 282 Volvo - 5.0L
« Reply #14 on: September 07, 2012, 04:13:48 PM »
Success! Test drive was uneventful. Firm pedal. No noises. No pulling. A 1/4\" more travel of the pedal than before; and less pedal pressure required to get the same stop -- predicted because of the slightly larger piston size in the Wilwoods. No leaks when I got back. I\'ll give it a few days and then bleed again just to be sure.

If we have any Volvo 240 fanatics down that way -- I have one more set of adapters for an upgrade like this.  $175+shipping AND you have to sign a liability release.....don\'t want your \"estate\" coming after me.  :)
'82 Volvo 242; '10 Cayman S; '15 Fit

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