July 2019-2020. Dual circuit disc brakes all round.
Including rear disc brake upgrade kit.
The master cylinder has 2 chambers, front and rear. The front chamber is connected to a hard brake pipe which goes to a
brass T piece fixed to a stainless steel bracket bolted to the chassis. 2 pipes go from the T piece to the through
chassis brake unions, then to flexible pipes connected to the front calipers. The rear chamber goes to a 2nd hard
brake line and on to the rear of the vehicle. This hard line is central and rear where it connects to a flexible
hose which has an integrated T piece at the other end. The T piece is above the diff and the T piece connects to
2 hard lines which each connect to flexible lines, the interface being fitted to weld-on brackets on the rear
axle. The flexible lines connect to the rear calipers. The hard brake lines are made from Nickel Copper pipe.
Brake system parts list (will fit most 15" wheels).
Brake cylinder with built in proportioning valve - from CPP - MCPV-1 master cylinder (CP31500-C 1" bore) ($199.00).
8” single universal booster / servo - from "Transmountracing eBay.com store
Front discs - TCI Custom 11" IFS standard discs painted silver.
Front calipers - "Wilwood D154 kit 140-12100-R" for 0.810" rotors (fitted to "TCI Custom IFS") from Summit Racing ($383.32).
Through chassis brake unions - connectors and right angle connectors are 910-31361 and 910- 91833 from Speedway Motors.
Front flexible brake pipes - JEGS 635005 18" pre-assembled brake hose with 3AN male to 1.5 male adapters" also from JEGS ($19.95 each)
Brake pipe - "Saville Brake Tubing" 90/10 Copper Nickel from eBay (£14.95)
Brass 3/16" T piece union - from eBay. Brass 3/16" inline union - from eBay.
Rear flexible brake hose with integrated T piece 91755591 - from Speedway Motors with two 3/8" to 3/16" adapters from eBay ($24.95)
Rear 11" disc brake kit - Summit Racing SUM-BK1623 for 7.5" 10 bolt axle, c-clip eliminator, small GM flange, non-staggered ($349.00).
Longer lug bolts for rear discs - "Dorman 610-259" wheel studs from Summit Racing ($14.99).
"MOTIP 04098" Red Brake Caliper Paint for rear calipers from Amazon.
"E-Tech XHT002-ET" Silver Extremely High Temperature Spray for front and rear disc rotors from Amazon.
Comma Dot 5.1 brake fluid from Amazon.
Front left and front right shown below.
Brake cylinder with built in proportioning valve, front and rear chambers.
Painting the Nickel Copper pipes with Chrome paint.
Through chassis brake unions and right angle adapters.
There is more information about fitting the front disc rotors and the calipers etc. on the
"fitting a TCI Custom IFS
" page. (Note this is a long page so scroll down)
and the upgrade to Wilwood calipers at "brakes upgrade Jan. 2020
Nickel copper brake pipe.
In the picture above, the brake pipe going under the T piece and disappearing off the left of the picture is the pipe from the
rear chamber of the brake cylinder and is going to the rear brakes. This pipe needs to be split to the two rear brakes and
this is done with a flexible brake pipe. This pipe is shown below and comes from Speedway Motors. Part Number 91755591.
("S" in the diagram above) It is fitted centrally and the integrated T Piece end will be above the rear axle / diff.
This pipe flexes as the rear suspension goes up and down.
Test fitting my wheels for clearance on a friends identical kit.
There is more information about identifying which is the correct rear disc brake upgrade kit for your axle.
It is particularly important to identify the end housing flange.
More information on the rear axle
Summit Racing rear disc brake upgrade kit.
Cleaning, heating and painting the rear calipers.
Test fitting the disc rotor before painting it.
Notes on painting the calipers -
The calipers were painted red. You can see below, they were masked and heated on a stove and then sprayed red
using "MOTIP 04098 Brake Caliper Paint". Having already used this paint on my car brakes, I knew how good it
was. When reading reviews on this paint, mostly it gets 5 stars but sometimes 1 star. I believe these people
are not cleaning the calipers properly before application even though they claim they have. They should be
cleaned with "Panel Wipe" from a auto paint supplier store. Since the caliper manufacturer puts a coating of
protective oil on the caliper, I have found they need cleaning about 4 or 5 times with panel wipe. Also using
cotton buds to get into the corners. Only when the soaked cloth is completely clean after the 4th or 5th
attempt will the calipers be ready for paint. Also note - use panel wipe in a well ventilated area and avoid
breathing in the vapours and wear gloves. Several coats of paint are needed, allowing about 30 minutes
between coats. The process can be speeded up with a hair dryer. Then wait several hours before removing
the masking tape. Put a thin coating of high temperature lubricant on any non painted masked up areas where
it was removed. (The protective oil was removed from some of the casting where the masking tape was placed
so that the masking tape would stick to the surface.)
Cleaning, masking and painting the disc rotors silver.
Notes on painting the disc rotors -
See notes above about cleaning the calipers. Once again use "panel wipe" to clean the rotors.
The E-Tech XHT002-ET" Silver Extremely High Temperature Spray is excellent paint. The same paint
(in graphite colour) was used to paint the "Sanderson" manifolds 18 months ago and
remarkably, they are still perfect.
Welding the hose brackets (included in the Summit kit) onto the axle.
Why flexible hoses between the caliper and the axle?
Clearly flexible hoses are needed at the front as they have to flex as the steering is turned. You might
say that hard lines could be used at the rear as there is no movement due to it all being suspended.
There are a number of reasons. The first is that this is the recommended method for the Summit Racing kit.
The hoses are included and the brackets with curved edges to fit on the axle are included. The second
reason is that all modern cars use this system. Therefore what are the advantages? If you need to change
a wheel bearing, or a disc rotor, or are even having difficulty changing pads with the caliper bolted on,
you can hang the caliper on a cable tie and since the flexi pipe is still connected there is no need to
disconnect the brake pipes, or lose the fluid, or have to refill and then have to bleed the brakes.
The most important flexible brake hose is the one with integrated T piece and is shown in the
diagram above since here, above the "diff", it has to flex as the suspension goes up and down.
25th Oct. 2020
- The work on the rear brakes will continue for another 2 weeks as we are waiting
for a part to arrive. More pictures will follow soon including more on the rear brake pipes and
also fitting the parking brake cable.
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