Boxster brakes on LP bug

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I posted on TS because of picture hosting, but can attach here:

Ive been doing this machining and others for over 15 years, so I figured I'd post on how I do it. I'm apprehensive in general due to the armchair experts, but lets see how this goes. :)

This setup is for boxster brakes on LP dropped spindle. The hub and caliper bracket are modified, but consumables (rotor, pad, caliper) are stock Porsche stuff, easy to find 10 years down the road. The spindles are modified for quality control but could revert back to drum brakes. The hubs are machined for regular bearings.

First up spindle check. Ive seen all kids of problems from tight/loose shafts to wrong threads machined (go figure). In this case the radius on shaft wasnt right and the bearing backstop off by more than a mm.

http://images.thesamba.com/vw/gallery/pix/1482301.jpg


http://images.thesamba.com/vw/gallery/pix/1482300.jpg

Heres other side:


http://images.thesamba.com/vw/gallery/pix/1482299.jpg

Measure difference

http://images.thesamba.com/vw/gallery/pix/1482298.jpg

http://images.thesamba.com/vw/gallery/pix/1482297.jpg

Put on lathe to fix:


http://images.thesamba.com/vw/gallery/pix/1482296.jpg


http://images.thesamba.com/vw/gallery/pix/1482295.jpg


http://images.thesamba.com/vw/gallery/pix/1482293.jpg
http://images.thesamba.com/vw/gallery/pix/

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Next cut the inner bearing

Indicate both ways (axially and radially)
http://images.thesamba.com/vw/gallery/pix/1482329.jpg


http://images.thesamba.com/vw/gallery/pix/1482328.jpg

Measure bearing size

http://images.thesamba.com/vw/gallery/pix/1482327.jpg

And cut to size

http://images.thesamba.com/vw/gallery/pix/1482326.jpg

More on bracket in next post

[flat]

Flip the hub over, indicate and turn for outer bearing. I forgot to take pics of that.

Next is the caliper bracket; cut, chamfer for spindle radius, countersink for spindle bolts, tap for radial adapter:


http://images.thesamba.com/vw/gallery/pix/1482330.jpg


http://images.thesamba.com/vw/gallery/pix/1484606.jpg


http://images.thesamba.com/vw/gallery/pix/1484605.jpg

Make radial bracket and test fit:

http://images.thesamba.com/vw/gallery/pix/1484604.jpg

http://images.thesamba.com/vw/gallery/pix/1484603.jpg

And thats about it. Cleanup, paint and assemble.

Hope that helps

[wrenchnride247]

Good post Lanner! I'm working with a set of those spindles on a build right now. The first thing I did was clean up that ruff grease seal surface.

[flat]

Good post Lanner! I'm working with a set of those spindles on a build right now. The first thing I did was clean up that ruff grease seal surface.

On the spindle? Yeah a polish helps. Post your machining pics please, what car is that for? I'll try and post more stuff and keep GL alive..

[wrenchnride247]

http://i52.photobucket.com/albums/g38/wrenchnride247/20160408_132600_zpsm99heejm.jpg~original (http://s52.photobucket.com/user/wrenchnride247/media/20160408_132600_zpsm99heejm.jpg.html)

Ruff!

http://i52.photobucket.com/albums/g38/wrenchnride247/20160408_133748_zpsbremlhfn.jpg~original (http://s52.photobucket.com/user/wrenchnride247/media/20160408_133748_zpsbremlhfn.jpg.html)

Polished up with emery cloth and finished with crocus cloth. VERY nervous with that hunk of steel spinning out there...only went 110rpm :nervous:

It's not a conversion to Porsche brakes or anything, just stock '63 drums...not my car. A friend just wanted it lower in front.

[Wally]

Nice!

[volkdent]

Thanks for the tutorial!

Jason

[flat]

No worries.

If I ever get back home I'll post more stuff. I'm part of the evacuees from Fort McMurray..been out of our home since we escaped the fire May 3. Hope to be back to town early June...and hope even more to still have a home and shop standing....