After some research and some good tips from Stef, this is whats required for the conversion:
- at least 15" wheels
- 2 Saab 900S 96-97 front calipers with mounting brackets
- 2 288X25mm rotors. They need to be redrilled to a 4-bolt pattern, and a hub insert pressed in
- proper tools incl brake bleeder kit, if assistant is not available
- 1l of DOT4 brake fluid
I am not going to describe the removal of the old wheels, just the assembly
Basic difference between the stock 256mm rotors, and the Saab ones.
Installation
1. Once the old brakes have been removed, clean the hub mating surface. This is critical, as the disc no longer seats on the uddge of the hub, but on the entire surface. This is why the center insert is required to fit over the hub, and keep the rotor in place. It simply must be clean.
2. Do a test fit of the rotors and use the wheel bolts to hold it in place. At this point, bent back the original rotor dust shield. Otherwise it will scrape againg the rotor surface.
3. Install the caliper mounting bracket. Use a snug-fit washer if you are upgrading Lemans, as the bolt head is round. In Lanos, this is not a problem as the swap does use the factory bolts too.
I had to get the Pagid mettalic pads, which is very well known in Europe. Hopefully someone from the other side of the pond will jump in, and perhaps provide some feedback of these pads.
4. Install the outer pad (remove the backing tape from the 3M applied to the outside pad. Not the correct position of the low-pad warning tab.
5. Insert the inside pad onto the piston. Apply some brake lube to the front side of the caliper.
6. Clean and lubricate the caliper sliders. Also clean and repack the rubber bushings. If they are cracked, they will need to be replaced. Use brake lubricant only. Regular grease will contaminate the pads and kill the brakes.
7. Insert the sliders into the bushings
8. Place the brake calipers in place and tighten the slider bolts. Reattach the brake hose. Use the original bleeding screw.
9. Securely insert the anti-rattle spring.
10. Bleed the front brakes (but you might do the entire car, since you are at it).
How good are they? I dont know yet. The car should be back on the road next weekend. But based on what I have found on the migweb, users have no problems locking wheels at high speeds, if required.
I will post the results from braking as do first 300km to let the new pads brake-in.
Enjoy!
