Disc Brake Conversion Timeline

Monday 03.11.2013 Evening
Car on stands
Drain diff

Tuesday 05.11.2013 Evening
Rear axles out
Bolt-on rear caliper adaptor brackets
Trial fit rotors and calipers

Wed 06.11.2013 Day
Purchase 2 x new rear axle housing seals
Purchase a new diff cover gasket
Purchase a replacement diff centre retaining pin
Purchase 10 x wheel studs
Purchase 10 x wheel nuts

Thu 07.11.2013 Day
Old studs removed
Purchase diff oil

Thu 07.11.2013 Evening
New studs pressed on axle
Remove rear disc hardware
File-finish axle housing flanges
Fit new axle seals
Refit rear disc hardware with new nuts
Refit axles with C-clips
Clean pin retainer and pin retainer cavity
Locate spider gears, insert pin
Fit pin retainer with Loctite
Fit hat with new gasket
Loose-fit calipers
Locate and measure rear brake line requirements

Fri 08.11.2013 Day
Purchase new rear brake lines

Sat 09.11.2013 Day
Fit rear brake lines
Fit new rear handbrake cables
Fit centre handbrake cable (retain existing front h/brake cable)
Fabricate new passenger side handbrake mounting hook (to suit short rear handbrake cables)
Remove driver side front drum
Dummy-up driver side front disc assembly

Thu 14.11.2013 Evening
Remove passenger side front drum
Relieve driver side mounting bracket to clear steering arm

Mon 18.11.2013 Evening
Bolt-up driver side front disc mounting brackets
Grease driver side front hub
Assemble driver side front hub and calliper/disc assembly
Relieve passenger side mounting bracket to clear steering arm
Bolt-up passenger side front disc mounting brackets
Grease passenger side front hub
Assemble passenger side front hub and calliper/disc assembly
Align and fit front brake hoses
Remove distribution block

Tue 19.11.2013 Evening
Remove existing master
Dummy-fit new master

Thu 21.11.2013 Evening
Remove existing booster
Enlarge holes in the firewall to fit new booster stud pattern

Sat 23.11.2013 Day
Dummy-fit new booster/master/combo valve
Make brake line templates

Monday 25.11.2013 Day
Purchase new front brake lines
Purchase 2 x blanking plugs

Monday 25.11.2013 Evening
Bench bleed master
Bolt in the booster/master/combo valve
Bolt in new brake lines
Fill diff with oil

Thursday 28.11.2013 Evening
Grind down the booster-master pushrod
Bleed brakes
Drive!

To-Do
Tack-weld rear axle housing tabs
P-clips for rear hand brake cables
Adjust handbrake actuators?