Rear Disk Brakes

 

Update 03-04-2010:Today I worked on the handbrake cables.

I discovered that the eye at the end of a beetle handbrake cable fits on the Golf handbrake lever.:

Handbrake testfit

It wasn’t meant like this, but it fits perfectly. And it can’t slide off.
Sadly, the part of the cable which isn’t covered by the outer cable is too long. The eye of the caliper handbrake bracket is to close to the lever for the beetle handbrake cable:

Handbrake testfit

But this can be solved by lengthening the bracket. I used a 12 cm long iron strip, which I will weld to the bracket:

Handbrake bracket parts

Once the bracket is lengthened, I will screw the handbrake cable to the strip with the little holder which is normally used to attach the handbrake cable in the beetle drums.
And so it happened:

Hanbrake bracket ready

Unpainted here, of course. Tomorrow I will dissasemble everything and paint it with hammerite.
At first I screwed the strip to the bracket with a M5 bolt, to determine the right angle (you can still see the 5mm hole). After that I welded the strip to the bracket and removed the bolt again.

I also welded a nut to the strip, which makes it easier to screw on the little handbrake cable bracket (the one that’s normally used in a beetle drum).

I cut off the original eye from the bracket, it’s not needed anymore:

Handbrake bracket ready

 

The outer cable is still long enough:

Handbrake bracket ready

The nice thing about this modfied bracket is that I can use the original VW beetle handbrake cables without modifications.

8 Comments

  1. I really like the website. Very informative. Great work on the car. My question is about the calipers. What year golf did they come from or are they all the same.

    • Hi Heath,
      I don’t know for which year they are. I just searched for rear brake calipers for a VW Golf IV.
      I assumed they were all the same… but I am not sure if they are.

      Greetings,
      Gerrelt.

  2. Hey Gerrelt,
    Thanks for the reply. I ended up going with 08 beetle calipers. They fit on the empi brackets perfectly. I would like to change the brackets to something with the same 0 offset as the empi brackets so I could buy the pads at the local parts store. Maybe Passat. Not sure. The 08 beetle calipers are much better than the empi calipers. The empis were thin and were flexing which caused the outer pad to not make up fully with the disc and was causing much noise and vibration. Next i’m going to add wildwood calipers to the front. I have the brackets orderd now. I’ll have a video up on youtube soon on the brake conversion. Ringo774. Thanks for the reply. Later

    • Yeah, I’ve read that before, the empi calipers aren’t very good apparently.
      And that’s the exact reason I used the Golf calipers too. Now I can get brakepads from the local parts store.
      I will check out your youtube channel!

  3. Hello Gerrelt,
    Thanks for this site, it is very useful. After reading it, I am doing the same rear disc brake conversion. I have one question: the Passat caliper brackets are from what YEAR of Passat? I ask because in the US, the Passat B3 was from 1988-1996, but I believe in Europe they used “Typ 3B” for 1998-2006. So it is very confusing: 3B or B3. If you know the year of the Passat the brackets came off, that would help me greatly. Thanks! -Matt in Virginia

  4. Perfect, thank you. I was working from the same (confusing) Wikipedia page. May I ask, how do you like the brake performance with this setup? And what brakes do you have in the front? My plan is to put Wilwood 4-piston calipers in front. My pedal assembly has separate master cylinders for front and rear,so I should be able to balance the front/rear brake bias by sizing the master cylinders correctly. -Matt

    • I really like this setup. I’ve got a firm pedal and good braking performance.
      In the front I have the standard VW beetle disk brakes and calipers, and I am using a standard (19mm, if I remember correctly) super beetle master cylinder.

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