924Board.org

[Tas931]

This is just a simple guide to show what i have done to install 4 piston Volvo Calipers on my 924 turbo. In this approach i drill the calipers so that a single brake line can be used. the other option is to create a 1->2 as in the orignal thread.

Volvo 4 spot weight (weighed on bathroom scales): 4.3kg

Here is the original thread/guide where they have been put on a 924. http://www.924board.org/viewtopic.php?t=25086&highlight=volvo

First step is to get yourself a set of the 4 piston brake callipers. I got mine off of a 264. You can also get them off a 244 or similar, pretty easy to tell, they are of the vented rotor with dual brake lines going to them (should look like the ones in the pictures obviously ).

Original on left, Volvo on right.


Take the calipers apart, i kept each caliper seperate, you should probably try and mark which piston came out of where as well. You will be left with a box of bits.



Next clean the parts. Make sure that you use something that will not disintegrate the rubber.

Now drill the Holes Take your time doing this and periodically check how far in you are. Using a reasonable size drill bit seems to be the key here, the length gives you the better angle and also the size of the hole allows them to reach sooner.

Here is the hole that is allready there that you want to make bigger.


Here is a pic from the other side, you drill back towards the other side untill they reach




But not too far.... This happened from using too small of a drill bit, it grabbed in and drilled straight through the other side.




once completed drilling i recomend using wet and dry (as you don't want to take any metal off) to clean/polish up the pistons and bores (including above the rubber), trying to avoid the rubber of course i used some 1200 and 2000 grit.

as for putting it back together, make sure everything is dry then lubricate the bore and piston with brake fluid and push back in, everything is pretty much reverse order from when you took it apart.

now all thats left to do is block off one of the old brake hose holes and your done. I am planning to go and get a blank during the week.

Sealed! I will be replacing that rubbish rubber you can see as well



Now mounted on the car and bled.



Then time to celebrate....

[Rich H]

Why not just use a T piece and use pipework to link them instead of drilling holes?
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

[macBdog]

What about using a workbench, gloves and a vice while you are at it.

I've drilled into my hand once, it's not fun looking at a spiral shaped piece of drilling swarf that came from your own body.
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1979 931 with a 350 chev
1973 911E with EFI

[Tas931]

@ Rich. Because that one is allready shown in the other thread i wanted it without the T piece.

@ mac. Agreed, but that isn't me. That person had their own pannel/work shop for many years and knows the dangers.