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Author Topic: Galant Brake Upgrade (Big Brake Kit!)  (Read 9335 times)

greywolf27030

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    • 88 Festiva, 67 Chevy C10, 91 Capri,
Re: Galant Brake Upgrade (Big Brake Kit!)
« Reply #60 on: July 31, 2017, 10:06:49 PM »

WOW

Jack Byrd
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SHOwn

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    • 91 XR2
Re: Galant Brake Upgrade (Big Brake Kit!)
« Reply #61 on: July 31, 2017, 11:25:51 PM »

I got the hubs back from the machine shop and they did not quite fit. I had them cut down .54" (dia.) but they caught on a ridge on the inside of the rotors, which Matt mentioned. I provided a rotor to test fit but the shop didn't take the hubs down enough. My coworker who just retired had previously run a machine shop and he finished them on his lathe for me.

However, I've been a little too busy to start the project, and everything is sitting on my bench. My OEM brakes still work decent with a small amount of pulse, and the pads have about 10k left on them, so I have a little time to get around to it. I would do the mock up test on my parts, but I have to put the seals on first and pack the bearings to get started, but I'm too busy painting my windows (house). I will try to post a completion to this project later this summer.

I probably won't get them on by the MACG, but maybe I'll throw them in the trunk for some discussion. I noticed that some said that NA knuckles are too small, but the 94 pair I have appear to be the same as my 91 XR2 brakes, but I won't be sure until I take off the XR2 brakes some weekend in August when I get back.
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R. Powell
'91 XR2, Liquid Metal 16" Chrome Drifters, White Gauge Faces, Kuhmo 40's, 2 1/2" Mandrel Bent CATback, BMW318i Heated Seats, `94 console, '99 Dodge Neon Spoiler, '94 XR2 Sideskirts Bumpers and taillights, Fresh Basecoat-Clearcoat Cardinal Red (Jul2014), vj11/vj14 hybrid, manual boost CTL.

SHOwn

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Re: Galant Brake Upgrade (Big Brake Kit!)
« Reply #62 on: August 20, 2017, 10:40:16 PM »

Ok BBU update. I've been enjoying driving instead of fixing the XR2 for the last half of the summer. So, here's where my big brake upgrade sits.


I decided to mock up the fitment with my spare knuckles from the 94 N/A I stripped. Well, some say N/A knuckles won't work, but I used them along with the old seal, the spacer and the old bearings which I honed out a few thousandths so I wouldn't need a bearing puller to disassemble it later. I was able to prove that the parts I listed do in fact work. The only modification that was done was to turn down the hub ears a little more than 0.54" so that the ears clear that inner ridge of the rotor recess.



The stock Escort loaded calipers did NOT need any modification at all, they clear the 266mm Galant rotors by about the thickness of a credit card when the caliper is bolted in place. The width between the pads is just exactly enough to take the Galant rotor with only minor contact like all brakes seem to rub lightly. The stock Capri caliper does NOT fit the thicker rotor being 1/8" tighter between the pads than the Escort calipers (which barely fit) are.


A little more measuring reveals where the Escort pads shine through. They measure at the same width front to back that is, but they are a full 1/4" taller than the Capri pads, and that makes all the difference. The two rotors are maybe 1/16" different in diameter, the Galant being only slightly taller, but those Escort pads take advantage of rotor meat closer to the hub that was unused by the Capri pads. Those Galant rotors weigh at least twice what the Capri rotors do, which is not good, but maybe it won't kill too much performance. I can extract some more boost to overcome the loss if I feel the upgrade loses performance.

I think I'll wait a few more weeks to pull the switch since we have 28th Street Metro Cruze next weekend (25-26th) in Grand Rapids. I'll be there and hope a few of my fellow Michiganders make it alongside me.
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R. Powell
'91 XR2, Liquid Metal 16" Chrome Drifters, White Gauge Faces, Kuhmo 40's, 2 1/2" Mandrel Bent CATback, BMW318i Heated Seats, `94 console, '99 Dodge Neon Spoiler, '94 XR2 Sideskirts Bumpers and taillights, Fresh Basecoat-Clearcoat Cardinal Red (Jul2014), vj11/vj14 hybrid, manual boost CTL.

chrispoe

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Re: Galant Brake Upgrade (Big Brake Kit!)
« Reply #63 on: August 21, 2017, 07:23:06 PM »

The piston in the Escort GT calipers is a larger diameter at 54mm vs the Capri's original 50.8mm, which gives more braking power with the same amount of force applied to the pedal.

One other modification that will be required is the Capri's hyd brake hose won't bolt up to the Escort caliper cuz the end fitting has a longer locator pin.  To solve this issue I just filed a slot in the caliper casting to accommodate the Capri's hose fitting. 
As shown in the pic by the red line.

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SHOwn

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Re: Galant Brake Upgrade (Big Brake Kit!)
« Reply #64 on: August 21, 2017, 09:07:26 PM »

Thanks for that important tip, Chrispoe, I'll check it out and grind it out before I start. Here's a few more views. I agree with the concerns some have expressed about the slide pin length. They do fit, but the Escort bolts were a little too long so I reused a Capri bolt and I did chew up one slide pin rubber seal in my trial but I have spares. If you look, you can see how much the slides protrude. I think it is a consequence of the size of the rotor and the pads being full thickness with shims included (they were loaded calipers). I could pull the shims if I want a little more leeway.





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R. Powell
'91 XR2, Liquid Metal 16" Chrome Drifters, White Gauge Faces, Kuhmo 40's, 2 1/2" Mandrel Bent CATback, BMW318i Heated Seats, `94 console, '99 Dodge Neon Spoiler, '94 XR2 Sideskirts Bumpers and taillights, Fresh Basecoat-Clearcoat Cardinal Red (Jul2014), vj11/vj14 hybrid, manual boost CTL.

WashiestSnake

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    • 1991 Mercury Capri
Re: Galant Brake Upgrade (Big Brake Kit!)
« Reply #65 on: August 23, 2017, 06:22:42 PM »

Couldn't you just swap the front brake hose to a Escort hose and not grind it down? I bought a set of stainless steel hoses with the intention of doing that. That's awesome to know that I can use my stock knuckles aswell, that means I'll be putting my BBK on soon!
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1991 Mercury Capri 68,xxx Miles--Project(AWD)
1996 Lincoln Continental -- The Boat(Given to my Brother)

SHOwn

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Re: Galant Brake Upgrade (Big Brake Kit!)
« Reply #66 on: August 23, 2017, 08:25:26 PM »

I've read a ton about this upgrade and somewhere I seem to remember something about the Escort hoses being too short. Maybe I can verify that.

Snake, do make sure that your N/A (if that's what you have) has the larger brakes. Apparently with N/A's it depended on what was on the shelf when they grabbed for front brakes when they were building them. Before you count on using those knuckles measure them - the 94 N/A rotors I pealed off measure 10-1/8" diameter.
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R. Powell
'91 XR2, Liquid Metal 16" Chrome Drifters, White Gauge Faces, Kuhmo 40's, 2 1/2" Mandrel Bent CATback, BMW318i Heated Seats, `94 console, '99 Dodge Neon Spoiler, '94 XR2 Sideskirts Bumpers and taillights, Fresh Basecoat-Clearcoat Cardinal Red (Jul2014), vj11/vj14 hybrid, manual boost CTL.
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