[4]

1982 Lada Niva

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i was finally able to get the white elephant out of the garage so i'll have space to work. First thing i did is to lay down some cardboard on the ground and place the axle housing on it after looking at it i know the brake discs will hang lower then it so i put it on some wooden blocks. Then i slide the axles in and placed the brake calipers, this show me what to do next, the easiest way is just to make a thick bracket and weld it to the axle housing, the caliper mount is so offset that i don't have a straight shot to the bearing flange and making an offset bracket is a hassle. So i made a CAD prototype bracket and test fitted it, next i'll make one of thin aluminium to make sure it fits well and then i'll make them from some 1/2 plate. Can't wait to have the little niva back on the road.
IMG_20190914_184356_1.jpgIMG_20190914_184645.jpgIMG_20190914_190554.jpg
 

jsh

Active Member
Registered
Joined
Apr 6, 2016
Messages
68
I am going from memory from more years ago than I like to admit. Circle track dirt car, we did sort of the same thing with rear disc brakes. I believe there is a particular angle for best braking as far as where your brackets are located. Maybe one of the racing guys will see this and have some input.
Jeff
 

Latinrascalrg1

Brass
Registered
Joined
Dec 9, 2016
Messages
890
I agree with JSH. I am in no way any type of authority on the matter but i did ask a ford brake engineer specialist once when discussing doing a rear swap to disc in my ram 4x4. Within his explanation one thing I remember him saying was amongst other potential problems the incorrect "angle of attack" (his words) could/would induce a bad wheel hop and lessen braking ability. I couldnt explain the whole concept as to why but listening to him made sense so please make sure to do a bit of research into this so you gain the Max safe Braking possible
 

Superburban

H-M Supporter - Gold Member
H-M Supporter - Gold Member ($25)
Joined
Jan 2, 2016
Messages
1,007
That goes through several ideas, but in the end, sums up my knowledge. Front axle, the brakes are generally the opposite side of the knuckle, from the tie rods. Rear axle,- independent suspension, is placed by the forces, exerted on the mounting points. Solid axle, can be any where.

Whether its placed on the front or rear, or towards the top, depends on the bleeder port, it needs to be at the highest position of the hydraulics.

On thing I am not sure of, looking at it only from a cooling issue, is it better to have the caliper in the major airflow (I'm assuming the rear side of the axle, with a rim that has lots of openings in it. Or is it better to have the caliper in the least air flow, opening up more of the rotor to catching air? My thinking would be the second, since most calipers do not have any type of fins, or other cooling features built into them, so the MFG is not as concerned about the caliper retaining heat.
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
I appreciate all the advice, i've been modifying and racing cars on the street before i even had a driving licence and the first rule in racing is your car needs to stop faster than it can go so i've done many brake upgrades and conversions most of them DIY using van and truck parts and the only real rule i've found is to place the bleeder on the top, i've had to switch caliper sides because van had the caliper on the front of the rotor and i had space on the back it always worked. In my opinion the hardest part of upgrading the brakes is to make the OEM wheels fit becouse i'm all about that OEM look.
 

jsh

Active Member
Registered
Joined
Apr 6, 2016
Messages
68
I had wondered about wheel clearance. All that work I was pretty sure you had checked. The off set of wheel centers is critical.
I recall a story a fellow put some after market wheels on and the car would not move. He fooled with the brakes for quite some time before he figured out the wheels were against the calipers,lol. Funny now but I am sure not at the time.
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
great quote......I'm gonna use that!
-brino
That is from experience, back in 2007 when i was starting to mess around with DIY turbocharging, i found myself with a snapped axle on the brakes with both feet missing a corner went down the embankment nearly missed the bridge and finally stopped there. That car resemble a banana after that, non of the doors worked it was so bent the roof looked like corrugated sheet metal too bad i lost all my old pictures couple years ago.
 

silverhawk

Active Member
Registered
Joined
Dec 6, 2015
Messages
252
That is from experience, back in 2007 when i was starting to mess around with DIY turbocharging, i found myself with a snapped axle on the brakes with both feet missing a corner went down the embankment nearly missed the bridge and finally stopped there. That car resemble a banana after that, non of the doors worked it was so bent the roof looked like corrugated sheet metal too bad i lost all my old pictures couple years ago.
I am glad you survived that one.

Sent from my SM-G970U using Tapatalk
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today after work i spent some time in the big and small garage, started with making the caliper bracket out of aluminium little more solid to test fit it . I made couple more adjustments and will slimline the bracket even more when i get it right i'll transfer it to some thick steel. Then i got back to my machine shop and continue making the suspension bushing ends and the inserts for them, you can also see the installation tool i made before, for now i've made 4 of them and i need to make 10 in total, they do take time to make because i'm making them from a solid piece.
IMG_20190915_133724.jpgIMG_20190915_115824.jpgIMG_20190915_133027.jpgIMG_20190915_133042.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i did a bit more machining. Started with a long piece of 4140, drill it and cut it to size i repeat this 6 times then chamfer the ends and moved on to making the big ends ( outside part of the bushings) as previous i made two at once as is more efficient use of time i have 4 more big end pieces to make and then meat them to couple of tubes to make the suspension links.
IMG_20190918_183113.jpgIMG_20190918_205247.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Last two days i've been cutting material for the lathe to have something to chew. First photo are the caliper brackets, i need to drill couple of holes in them and they are ready to be welded, they were very difficult to cut with a 4" grinder. Next are couple of round plates that need to act as spacers for the drum backing plate. A last is couple of pieces to take the space of the drum it self. I've given my angle grinder a good workout cuting all of them.
IMG_20190920_193727.jpgIMG_20190920_193751.jpgIMG_20190920_193821.jpg
 

Firstram

Active Member
Registered
Joined
May 26, 2018
Messages
111
I've never mentioned it but, I love how most of your parts and new tool acquisitions are staged on the lathe for pictures.
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
My table is always a mess, and the lathe is at the right height, also is not reflective so makes the perfect place to take pictures.
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i stopped by a parts store and bought new handbrake cables for the little niva, the original ones are close to 40 years old and i need to to modify them for the disc brake conversion so i'll rather start with a fresh set as for the quality, you can see russian workmanship.
IMG_20190922_094224.jpgIMG_20190922_094234.jpgIMG_20190922_094241.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
I've been really busy at work, and that has slow down the pace on finishing this project but i've managed today to get something done, started with machining the rest of the bushing material, also drill the inside. Then i moved to the useless drill press and managed to get all the material drilled so i can mount them in the lathe and on the axle.
IMG_20190923_195140.jpgIMG_20190923_201645.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i had a choice to do a bit more machining or weld on the brackets for the brake calipers. After a coin toss i started on the axle housing. I remove the axles, grounded off the paint, and had to make a puller to remove the axle seals and after a short fight with them i removed them, then i assembled everything back on and welded the brackets, a quick clean up and i gave them a coat of black paint. I did lot of measuring and checking when poisoning the brackets and after welding them.
IMG_20190924_203515.jpgIMG_20190924_203535.jpgIMG_20190924_203527.jpgIMG_20190924_203924.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i'm back machining parts for the little niva's rear axle. First i threded the holes i drilled earlier then i attached a bolt and chucked it in my lathe then i installed a securing nut to be on the safe side, after then it was pass after pass taking material off, i'll get both pieces like this then switch my jaws and do the other side, i also did some work on the other two pieces of thin steel but that will not work out they are very bent, i'll scrap them probably.
IMG_20190926_200143.jpgIMG_20190926_201048.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i decided to switch things around, and do a bit of assembly rather than machining, so i got hard to work assembling the rear axle. Started with installing new oil seals for the axle shafts, then remove the masking tape from the hole for the centre section prep the surface apply a bit of silicone on both sides of the new gasket and assemble it, i also clean all the bolts and torqued them to spec. Then i installed the half axles, torqued them and the brake calipers. After that i started on the new brake lines, started with the flex lines, and the original one on the axle to the car then i got out all my spare lines and started measuring and matching hand lines, i had to flare the end on one side and that side is done, as for the other i'll get to it later on because i was too tired to be hand bending brake lines any more. I'm still waiting on a left handed threading die to make an adjustable panhard bar for it. Parts assemble rather quickly when everything is prepared and ready.
IMG_20190927_205215.jpgIMG_20190927_205226.jpgIMG_20190927_205236.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
There's nothing like the weekend to mess up your schedule. The plans to have the little niva up together ready to drive come and went but i did manage to get couple of things done, first i determine which pipes and tubing i'll use to make the new suspension links, the round pipe is seamless, roll cage material very thick wall staff, the lower suspensions links are first things to get damaged when off roading so i plan made them from the biggest strongest square tubing i could buy. Then i realised i don't have a piece for panhard bar so i drove to my metal supplier and bought me a piece. When i got back i started planning, i drill and tap couple of holes in my table so i can bolt down the ends in the right spots then come the part that i hate that is shaping the ends to match the curves of the bushing ends so it will have more surface area to be welded on. By the time i got finished with the third bar it was almost midnight so i stoped.
IMG_20190928_185546.jpgIMG_20190928_185555.jpgIMG_20190929_092406.jpgIMG_20190929_092413.jpgIMG_20190928_204734.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i finish grinding on the bars i had started. Then i bolted down the bushings sleeves, place the bars and welded them, i did 2 passes on most of them at 160a where my mig welder maxes out not the prettiest welds but should be stronger than the originals also the materials are thicker and better quality also no rust. I wanted to paint them today but they were too hot to handle. As for the panhard bar i need to start on it, the plan to have an adjuster with left hand and right hand thread may have to change as china post lost my threading die, so i may make ti single thread so it needs to be unbolted to be adjusted.
IMG_20190929_183401.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Thank you AL, unfortunately yesterday when grounding the tubing the cutting stone cracked and a small piece got in my eye, has happened many times before but this time i couldn't get it out myself, so i went to the hospital and got my entire head wrapped in bandages to hold the eye patch this took all the time i had for the day i'll be more careful next time. My eye should heal in a few days if i did not catch a cold from all the others in the hospital fingers cross.
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Yeah, next time i'll duck quicker, i'm not big on safety. That says i managed to ground the suspension links, wipe them down with acetone, paint two coats of black primer and one top coat of grey/blue. Using only one eye to paint and doing everyday tasks like driving is challenging my depth perception especially at night is bad. Thankfully the doctor said few days should be back to normal.
IMG_20191002_191415.jpgIMG_20191002_191357.jpg
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Today i finally got all the bandages of my eye and could see, a bit fuzzy but better then reaching for a door handle a metre before the door. I thought it will be unsafe to work on the lathe so i got to pressing in the new poly bushing in the suspension links, they put on a good fight, they are much tougher than rubber, pressing the sleeve in the middle made them mushroom at the ends but should be fine i got them all dirty and oily from the grease i was using. Then i got to work on the drivers side brake line, i cut it to size bend it installed couple of rubber sections as insulators, installed the fitting and flare the end now the rear end can get installed.
IMG_20191004_182038.jpgIMG_20191004_203618_1.jpgIMG_20191004_205324.jpgIMG_20191004_210635.jpg
 

just old al

Chaos Merchant
Registered
Joined
Mar 17, 2017
Messages
84
When it comes to fitting polybushes like that (we use them a lot in Land-Rovers) water with dish soap works very well as a lubricant. Just an FYI...fitting those is a lot like fitting a tyre on a rim.
 

GoceKU

Bronze
Registered
Joined
Jul 14, 2017
Messages
1,094
Yeah i did use liberal amount of lithium grease, on the bore, on the bushings on the sleeves and is different than stretching a tire, this is squeezing a bushing thru hole half its size, they are advertised to outlast the vehicle i'll see if that's the truth.
 
[5] [7]
Top