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jomac
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I engineered this setup from off the shelf calipers and rotors with working emergency brake. Designed custom mounting plates, they are bolt on but can be welded. Will weld on after testing period.

Attachment: IMG_0717.JPG (Downloaded 308 times)

Frank Schwartz
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Great !!! Tell us more......(such as..specs and drawings???)

Frank

jomac
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Working on providing details

jomac
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Working with a supplier who will make laser cut brackets, you can order direct from them. Installation document will be done soon. Hang in there!

atgparker
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Awesome stuff! Please advise on caliper and disk used. Been looking at this modification for quite some time but looks like you found a disk rotor with 4 x 4.00" bolt circle and a usable offset, bravo. Counter sink the lug holes and use conical seat lug nuts to center disk and then I'd drill in four counter sinks and tapped holes in the flange to assure it stays on center or perhaps design up a light press-fit bushing to center it on the axle shaft boss.

jomac
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I finished may assembly guide what use and did, also received a quote from a laser cut source. Only leaves me with getting samples of their parts to make sure they fit. The rotors are on 100mm bolt circle, however their clearance hole is large enough for exact fit to outside edges of lug studs to center rotor on hub plate. I test drove a lot and everything performs well. The pedal pressure is stiffer. I also included a rear proportion valve,

Frank Schwartz
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Wonderful !! A really nice addition to the JH...looking forward to the "whole package" of parts list and laser cut parts..

jomac
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Thanks for everyone's interest in rear disc. I Will talk with the laser cut supplier monday, should have everything together this week to release PDF on installing rear disc brakes.

jomac
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I have a PDF on how I did my rear brake conversion. Send a request to me at: 07vette47@gmail.com
I'll email you a copy.

t4brew
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Great work!

I have been looking into possible brake upgrade solutions also and have some prototypes for front and rear brakes using Honda/Acura calipers with various rotors. I also came up with a prototype for some Wilwood calipers. My problem had been lack of time to move from prototype to production.

I have some pictures at:

http://www.jhppg.com/mediagallery/album.php?aid=516&page=1

I created a brake upgrade pdf here:

http://www.jhppg.com/mediagallery/album.php?aid=475&sort=0

Maybe this can help other people looking into how to upgrade your Jensen Healey brakes.

If people are interested I can post more details about the caliper adapter brackets.

Bluekaos5
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HiSpec Motorsports in England has posted a new single piston rear caliper with an electric e-brake which they say will be available summer 2017. At 770 GBP for calipers, ECU and wiring cables; its a bit pricey but this would definitely cut out a lot of headaches engineering and fabricating e-brake linkage/cable.

http://www.hispecmotorsport.co.uk/electronic.html

Last edited on 04-03-2017 03:27 am by Bluekaos5

atgparker
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Got the honda CRX brakes worked out but with the Honda OEM emergency brake cables and pitched the JH cable and rod as it doesn't really work on floating calipers.

The bracket welded to the axle sets a perpendicular line that is through the caliper fixing holes at 45° to the horizontal. So the angle is a bit steeper than Jomac's but should allow for better bleeding of the air from the caliper.

This angle also allows the cable to clear the frame and radius arm as it passes around the coil spring at ride height.

Also the added height of the caliper allows the Centic brand banjo bolted brake line to bend to a nut I welded to fix the tab for the lines routing to a tee that is yet to be procured and mounted on the diff-housing.

Attachment: WP_20170513_002.jpg (Downloaded 93 times)

Last edited on 05-15-2017 02:24 am by atgparker

atgparker
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CRX OEM Brake cable bracket fabricated from some 1.00" wide steel strip, a wave washer flat washer and E-clip retaining ring.

Attachment: WP_20170513_004.jpg (Downloaded 91 times)

atgparker
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Emergency Brake Cable Management using the OEM CRX cables. note the upper control arm bolt is utilized for the bracket fixing. The cables come with three bent up retainers two are located on steel keepers that allow the axial location of the cable to be controlled.

I cross the cables to open up the bend radius so the passenger side cable at the caliper enters the driverside of the tranny tunnel and vice versa for the driver side cable.

Attachment: WP_20170514_001.jpg (Downloaded 91 times)

Last edited on 05-15-2017 02:06 am by atgparker

atgparker
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Twin Cable to Handbrake lever modification. All thread passes back through OEM cable hole with tubing slipped over the all thread to keep rattles to a minimum.

The OEM JH header plate is replaced with a new one I fabricated form the same .190 x 1.00 steel strip. It has three 1/2" holes and two to allow the OEM screws to fix it to the unibody.

The CRX cable housing ends are close to 1/2 inch OD and are set 4" apart on center with the cables original hole so that the offset in the tranny tunnel is maintained. Its slightly to the left of center or nearer to the drivers side.

I had to add a swivel pivot to allow for cable length miss-match to equalize. It is made of some 7/8 OD aluminum rod with a 3/8 hole drilled through for the all tread to pass through with a bushing to ride against it. This keeps the slot in the square steel tube to a minimum to allow the bar to yaw as the cables are not the same length when you remove the slack.

Attachment: WP_20170526_004.jpg (Downloaded 57 times)

Last edited on 05-27-2017 05:00 am by atgparker

atgparker
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Cable routing from caliper to pivot axis of upper control arm bolt. It was like these cables were made for the car.
Note the rubber bonger on this section of the cable at mid span between the frame and radius arm.

Attachment: WP_20170513_003.jpg (Downloaded 90 times)

Last edited on 05-15-2017 02:26 am by atgparker

atgparker
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Header plate used to secure cable outer housing in the tranny tunnel.
Those stepped sheet metal hole-saw's are the ticket for popping in the new holes in the cars sheet metal.

A good drill press and some pilot hole drilling gets things close enough to make things fit.

Attachment: HEADER PLARE FOR JH USING CRX E-BRAKE CABLE.jpg (Downloaded 89 times)

atgparker
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Adapter plate for the caliper on the axle housing.
This took three tries in thin plywood on a scroll saw to perfect for the cable angle and the hydraulic lines bend radius. Notice the piston on the caliper and the ID and OD of the swept area are included in the SolidWorks Drawing to optimize the brackets mounting hole position.

Making these out of 1/4 steel plate is no small feet and took most of a weekend to manage with basic hand tools, a saber saw and a 4 inch disk grinder.

PM me for pdf's of these drawings if you want to manage this approach on your Disk brake conversion.

Attachment: PLATE ADAPTER JH AXEL TO CRX CALIPER.jpg (Downloaded 89 times)

Last edited on 05-15-2017 02:51 am by atgparker

atgparker
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Hydraulic line routing to chassis

Attachment: WP_20170526_005.jpg (Downloaded 59 times)

atgparker
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Brackets for holding Centric Flex lines with M10 x 1.0 Thread adapters to 1/8 NPT.

All that lovely new bed liner paint on the axle needed something to set it off. Chromed hex head 1/4-28 machine screws for the differential cover!

Attachment: WP_20170526_006.jpg (Downloaded 58 times)

Last edited on 05-27-2017 04:50 am by atgparker

Wizardwings
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I have received the file from jomac and taken his drawings for the mounting plates to a shop to have water jet cutouts made, if any one is interested i can have others cut at the same time, I dont know the cost yet but if your interested, let me know.

jomac
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Rear Ebrake installation, I sent out a revised version 1.0 to all I sent out copies of the first version. I added a tactical and tuning section . I added 2 rear springs to the Ebrake cable, one compression the other tension. The reason was to take up the slack when using the original JH linkage. Tight adjustment is key I set my Ebrake to slight drag to rotor and after driving they seat themselves. My Ebrakes perform same as stock .
Also, crosscar Ebrake rod shape does not interfere with bump stop, when using my caliper bracket design angle, it was setup to clear other components any change higher or lower would impact your install clearances.



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