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Aurora Brake Upgrade - Rear
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Written by 63viking - AACA Reatta Forum
Wednesday, 07 January 2009
 

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I
started with 2001 Olds Aurora Calipers and drilled and slotted rotors. The parts  from any of the big GM cars from 1995 up to 2003  with disk brakes should fit. 

I try to collect all parts first and get them organized before I start a project.

Parts needed:
  1. Two calipers, I believe both are drivers side calipers.
    • When mounted, both calipers must have the actuating arms facing up.
    • The driver’s side mounts on the backside of the caliper and the passenger’s side mounts toward the front of the car.
  2. One piece 1-½” wide x 1/8” thick, flat steel 18” long or longer.
You will need various tools to fabricate the two cable mounting brackets.

Tools I used:
  • grinding wheel
  • hacksaw
  • files
  • drill bits up to ½’
  • Vise
  • hammer
  • gloves, and safety glasses
Installing the calipers:
  1. Remove both stock calipers and rotors completely, leaving only the cable and the brake hoses.
  2. Prepare the work site by cleaning, painting and removing any rust or debris.
  3. Mount the calipers on each side. Make sure that the actuating arms on both calipers are facing up. 
    • On the driver’s side you will need to remove the actuating arm and turn it upside down. You will need to grind away a little on the stop for the arm to fit correctly. Next mount the actuating arm and bend it up slightly to clear the caliper when it moves. Stretch the return spring around so it makes contact with the arm.

      The passenger’s side caliper mounts toward the front of the car

Fabricating the cable brackets:

Let’s start with the driver’s side bracket. It needs to be 4 ½” long to the 90’ bend. The bend should be about 1 ½” at a 90’ to the straight. Total length should be a little over 6”.  Next drill a ½” hole in the bent end.  (you will have to open this up just a hair for the cable to lock into.) You might drill this hole a little higher up than I did. I think you might get a better angle with the cable.
The bracket will also have to be cut down to clear the actuating arm. See pictures. The mounting hole at the other end is 3/8”. Before you drill this hole make sure that you have the correct length cable to reach the arm and that the arm clears the caliper.

rear_brake_upgrade1.jpg
Photo of drivers side

The passenger side is straightforward, just be sure you have mounted the caliper with the actuating arm facing up. The bracket for this side should be 5 ½” long to the 90’ bend. Drill a ½’ hole in the 90’ bend. Check length for cable and drill 3/8” hole to mount. This bracket also needs to be cut to clear the actuating arm and cable. See pictures.

Before drilling the 3/8” mounting hole make sure that you have enough cable to reach the arm. I would double-check it.


rear_brake_upgrade2.jpg
Photo of passenger side

When the wheels are down to their extreme the brake hoses are a little taut and close to the calipers. I put plastic hose over them for protection. I have not adjusted the cables. If you make the brackets long enough to take up all of the slack you shouldn't have to.

Check all bolts and connections for to ensure they are tight and check cables and hoses for binding before driving the vehicle! It is your responsibility to be sure this modification is safe!

 

Last Updated Tuesday, 16 November 2010

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