C5ALIVE Forum

C5Alive General Category => C5 Chatroom => Topic started by: jk on 20, March, 2012 - 04:22:51

Title: My front disc brake and axle
Post by: jk on 20, March, 2012 - 04:22:51

G'day,
Well I finally got around to finishing my C5. It took a while, but with many projects in between, I finally got there.
I have been using it to get to work a few times and I must say, I get a fair few looks. No one knows what a C5 is down here!
I thought I would show you my front disc brake and axle assembly I made.
(http://i1026.photobucket.com/albums/y329/yaknosaj/IMAG8370.jpg)
I replaced the entire axle assembly with one that I made. It consists of a aluminium sleeve with recesses to fit sealed bearings, a disc brake boss which is bolted through the the plastic hub and into the sleeve, and a new steel axle machined to fit and retain the bearings.
(http://i1026.photobucket.com/albums/y329/yaknosaj/IMG_0227.jpg)
The entire assembly, split apart, looks like this, other side similar.
(http://i1026.photobucket.com/albums/y329/yaknosaj/IMAG8374.jpg)
The design is copied from my mountain bike front axle, but with smaller bearings. In fact, the brake boss was machined off of a broken mountain bike hub. The bearing dust caps were also from that same hub.

I used an Avid BB5 rear disc brake set, the rotor is 140mm. It is nice and smooth in operation. The caliper bracket was made from a scrap peice of 3mm mild steel cut to shape and welded on.
(http://i1026.photobucket.com/albums/y329/yaknosaj/IMAG8375.jpg)
Hope you like it!
When I get time, I'll split apart the gearbox I made for all to see...
Jason

Title: Re: My front disc brake and axle
Post by: Lancealot on 20, March, 2012 - 05:53:30

Nice job mate.................

I like it and wish I could do it to some of my C5's. Especially the 24v conversion I am doing.

Cannot wait for the gearbox...................

Keep up the good work.

Lance

Title: Re: My front disc brake and axle
Post by: rafarestaura on 20, March, 2012 - 06:51:00

Really good job, very professionaly finished  8). I need one like that to increase brake capacity going down the hills of my city, I´ll try to go under your steps.

Regards, Rafael

Title: Re: My front disc brake and axle
Post by: C5 ENTHUSIAST + RESTORER on 20, March, 2012 - 07:42:18

Well done great job ..I want one ...Chas

Title: Re: My front disc brake and axle
Post by: Thor069 on 20, March, 2012 - 12:45:24

Hello,

nice and well done job, i woould like to have aslo this break to go down in my garage with mor safty.

Best regards.

Thorsten

Title: Re: My front disc brake and axle
Post by: kamilb1998 on 20, March, 2012 - 15:50:20

Great job! Will certainly be useful when going down hills  8)

Title: Re: My front disc brake and axle
Post by: Retro Andy on 30, March, 2012 - 09:52:05

Looks a really nice mod, top stuff  :)

Retro Andy.

Title: Re: My front disc brake and axle
Post by: Karl on 31, March, 2012 - 09:49:43

..on a side note , this conversion gives a whole new lease of life to those front wheels with brake damaged rims.