Fitting 944 brakes

I am fitting early 944 brakes on all four corners, probably with a 911 SC master cylinder. I bought a complete rear axle from an early 944 so I also get the trailing arms with their adjustable spring plates. The brakes are ventilated discs with single pot calipers. The rears will be a bolt on swap (once I have added the IRS brackets), the fronts will require a bit more work.

944 rear disc and caliper assembly

The arms will clean up well, they are just covered in road grime.

This is the complete rear axle from a 944, the torsion bar and trailing arms come off the car as a subframe.

Front parts shown with a drum brake spindle from a beetle, this is used due to its flange being better suited to adaptation for the new caliper.

These are the wheels I will use all round. I wanted to keep a stock appearance and these have a big enough offset to cancel out the increase in track of the 944 brakes (24mm per side). I will have them powdercoated in silver shortly so they will look very similar to 356 'C' wheels. They are 15" x 5,5J with a 53mm offset.

I am using the 944 master cylinder for the increased volume of brake fluid required by the new calipers. I may end up swappign the outputs around so the bigger circuit goes to the rear brakes as my weight distribution is quite rear biased.

This is the above wheel after blasting, powdercoating and then laquering. I can definitely recommend 'Bourne Powdercoating' in Birmingham, they only took a few days and was only £15 a wheel!

I have ordered some Bridgestone Potenza tyres in 195/60R15 to go with them form mytyres.net.

Just for you Mike!

Here are the front DRUM spindles with the rear spot-aced for the caliper adapters. I will post detailed drawings of the parts needed for the complete front swap once I have checked them. They should be ready next week! I have stripped back all the calipers and repainted them already.

Here the inner bearing has been pressed in with its spacer.

Outer bearing fitted.

The drum brake spindle needed sliught clearancing, the raised ring fouled the back of the 944 hub.

Assembled spindle with spacer fitted. I am using spacers as I want to use the same wheels on all corners. The spacers are off the rear hubs, they needed modifying to fit on the front hubs.

I did a quick measure of the beetle and converted hubs and the increase in width (without spacers) is actually quite small, if anything.

Fitted to the car.....

You can't make it out, but the speedo cable sits through the Porsche cover plate.

The 944 master cylinder was necessary, as the beetle one did not have enough volume for the front calipers. Although, the beetle master cylinder IS fine with 944 rear and beetle front discs. It was necessary to fit a T piece to keep the brake light switch, I did this in the rear line as the one that was fitted was too short to reach the rear output on the 944 m/cyl.

 

Engineering drawings for the bearing adapters and modifications to the 944 hub.

Exploded view showing unmodified VW spindle and 944 hub with VW bearings

Bearing adapter drawing: note that the tolerances for fit should be measured from your hubs and wil be press fits.approximately 0.04mm over the size of the hole

Modifications necessary for the 944 hub: I can supply the necessary new hub seal, it is narrower than the 944 seal and is a standard fit between the beetle spindle and Porsche hub

The caliper adapter dimensions are easily availabel from several books so I won't repeat them.