The Mk1 ABF Project

[ByronRichesMk1]

That looks heaps cool!!

[cartertronic]

That looks heaps cool!!

Thanks mate! Although I don't think I'm going to bother putting them on now haha!

Had a win at the wreckers today, when this flash of red caught my eye...


It's a 1993 Calibra 2.0L 16v (nicknamed a 'redtop' for obvious reasons), which came standard with 256mm Girling brakes. Pretty rare in Australia, as I think we only got the 2.0L 8v and 2.5L V6 .. so must be an import.




Was there to get a radiator hose for the ex-Mrs, so had to go back home for my full kit.. $60 is a bargain anyway you look at it



These bolt straight up to Mk1 hubs, I'll just need Mk2 256mm discs and some shoulder bolts (12mm diameter x 25mm, thread is M10 to fit mk1 hubs). The Calibra flexi-lines also fit to the Mk1 brake line


Or cut some 12mm pipe as sleeves..


Should look like this once done (although I'm thinking blue )

(these last 4 pics from The Mk1 Golf Owners Club.. see second link below)

Hopefully they fit underneath my 15 inch Ronal R10s!

For anyone interested, keep your eyes open for any of the following:
1988 - 1995 Vectra 16v (GSI)
1984 - 1990 Astra 16v
1988 - 1997 Calibra 16v


For more info see:
The Mk1 Golf Owners Club - Vauxhall 256mm Front Brakes Part 1
The Mk1 Golf Owners Club - Vauxhall 256mm Front Brakes Part 2
VW Caddy Forum - Chavalier calipers
VW Caddy Forum - 256mm brakes for everyone and cheap as chips

[GoLfMan]

nice score mate! I'll be keeping an eye out for them.

[cartertronic]

Anyone got any recommendations about buying 256mm discs?

[roccodingo]

Anyone got any recommendations about buying 256mm discs?

Have them on the shelf here mate. PM me a mailing address and I can get you a price.

[cartertronic]

Have them on the shelf here mate. PM me a mailing address and I can get you a price.

Cheers mate, PM'd..

Anyone have any experience whether it's worth bothering with drilled/grooved discs? I can't imagine 256mm discs will get hot enough to warp when stopping 850kgs of car

[mikinoz]

Overkill is endorsed. These are on the rear of my MK1

[cartertronic]

Overkill is endorsed. These are on the rear of my MK1

They do look mean as hell

What brand are they?

[Peter Jones]

Anyone have any experience whether it's worth bothering with drilled/grooved discs? I can't imagine 256mm discs will get hot enough to warp when stopping 850kgs of car

Depends what speed you're stopping from.

I've got EBC dimpled and grooved 256mm discs on my white Golf. They get very hot with no issues so far.

[cartertronic]

Hmmm...do want 'em, but bit low on cash

In other news, picked up bolts, washers and loctite from Metro Bolts in Richmond.. looking forward to fitting it up!



PS - Bloke recommended 222 to stop vibration, will this be strong enough and resistant to brake heat?

EDIT - Found some info on http://au.iloctite.com/en/red-loctite-threadlocker

"What is the thermal resistance requirement for the assembly? If the heat resistance in excess of 300°F (150°C) is needed, it is recommended that Loctite® 272 Threadlocker to be used."


and then this..

"High-temperature threadlocker Loctite® 272 can be used up to 232 ℃, If you want even higher thermal resistance , then the ultra high temperature products, such as Loctite ®2422 (medium strength) and Loctite ®2620 (high strength) which withstand continuous exposure to temperatures of up to 350C should be used."

Found this technical data:

Loctite 222 Technical Data PDF media.midwayusa.com/pdf/instructions/Loctite_222.pdf
Paying attention to the heat strength and aging graphs


So based on that, it drops to a minimum of 25% effectiveness when applied to calipers

Loctite 272 Technical Data PDF www.reyher.de/download/Technical_data_sheet_Loctite_272.pdf


Loctite 2422 Technical Data PDF
65.213.72.112/tds5/docs/2422-EN.PDF


Loctite 2620 Technical Data PDF
65.213.72.112/tds5/docs/2620-EN.PDF


Looks like 2422 improves at 350 degrees.. interested to know what happens after that!

What do you guys use?

[cartertronic]

Just answered a PM about freight charges etc., thought it beneficial to post it here:

In response to 'how much did it cost to import the engine?':

"It's difficult to say, as I shipped a 2m x 3m crate with heaps of other stuff inside:
-1997 Mk3 GTI (bought whole car) = 461 GBP
-Towing = 165 GBP
-Crate = 240 GBP
-Shipping = 440 GBP
-Customs/Local Freight Handling Fees = $830AU (incl. fumigation charges)

In all honesty, if I had to buy another ABF I would source it locally! Unless you need to bring in a whole lot of other bits and pieces, it'll definitely end up costing you more in time and money... then there's the hassle of arranging it etc.

Either that, or try to find someone with a container coming to Australia, that way you might be able to skip likely hassles with customs...

A word on customs: After picking up my crate that had been literally torn apart by customs officers and reorganising all the items inside that had been piled back in the remains of the crate (damaging several items), I spoke to the freight handler..
He said customs officers actively target small private crates as these are most common for amateur criminals bringing in illegal items/drugs etc. Apparently they also "high-fived" (he witnessed their inspection) when they found a bug, as this means they can charge fumigation fees."

EDIT: Just looked at my original thread post where I said I was planning to keep it under $3000! If you just include the above the total is $2800... mission accomplished (if you exclude the bucket loads of cash I spent on other bits and pieces haha! )

[cartertronic]

Couple of goodies arrived today

VR6 Water Pump Pulley (for power steering and air conditioning delete - since getting a daily driver I've decide not to go down the track of installing AC)


..and Mk2 256mm Brake Discs (to go with the Calibra 16v calipers and carriers!)

[roccodingo]

discs arrived all good mate

[cartertronic]

discs arrived all good mate

Thanks mate!


..also picked up rear disc setup from Dom today, now to find time to fit it all up!

[cartertronic]

Was clearing space in the garage last night and noticed the rear mount bracket (bolted to the transmission) is broken.. not sure how that happened

That flat piece that sticks out should have two holes for the rear engine mount bolts!



(or perspective of where this bracket is located...


These should be a dime a dozen, anyone got one lying around?