drum to disc conversion

1961-1968: a.k.a "Finnie" or "Heckflosse" models
190, 190D, 200, 200D, 220b, 220Sb, 220SEb, 230, 230S, 250SE coupe, 280SE coupe, 280SE 3.5 coupe, 220SEb cabrio., 250SE conv., 280SE cabrio., 280SE 3.5 Cabrio., 300SE, 300SE coupe, 300SE conv., 300SEL
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sf0999
250s
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Model you own: w111
Location: Windsor, Sydney

drum to disc conversion

Post by sf0999 » Sun 27 Aug, 2017 9:45 pm

Hello All, I'm converting the early Finnie from 4 drums to 4 discs. Most hard parts have come via Cam and Drew -thanks guys. I have the clutch and single brake booster on the firewall with the drum system, which presents a challenge to install a conventional brake booster. I have a new split system master cyl, but I can not flit a booster in front of it with the clutch master cyl so close. I think the later models had the clutch cylinder mounted under the dash (which means replacing the pedal hardware at a guess). The inline booster is still serviceable, but with a slit system it will only be boosting the front circuit. Open for ideas an suggestions on the best way forward. Cheers.
W111 1961 220S Classic Rally Car "Eugen"
W126 1988 300SEL "Frankie"

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Mercmad
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Re: drum to disc conversion

Post by Mercmad » Mon 28 Aug, 2017 12:10 am

Use a VH44 Booster ,made by PBR in Australia, dont be tempted top buy chinese made ones. , You need to make three new pipes to feed both front discs with a seperate line to the back from the booster. The VH44 is the smaller unit, the next size up is the VH40 (a cuustomer of mine just fitted a VH90 to one of his projects!) and it comes in amny different variations so you need to contact PBR to get the correct version. what i do have here is a W115 with a 250 engine and fourspeed manual trans, it has the firewall booster setup etc. If it is of interest to you,I want to get rid of the whole deal(it runs well but the body is shot)

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Bartman4800
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Re: drum to disc conversion

Post by Bartman4800 » Mon 28 Aug, 2017 12:42 pm

sf0999 wrote:
Sun 27 Aug, 2017 9:45 pm
Hello All, I'm converting the early Finnie from 4 drums to 4 discs. Most hard parts have come via Cam and Drew -thanks guys. I have the clutch and single brake booster on the firewall with the drum system, which presents a challenge to install a conventional brake booster.
If you have front drums you should have a remote booster in the front left of the car.
Did someone convert it to a newer version booster before?

Bart
1963 220 Sb Sedan "Kermit" (Australian Assembly)
1960 220 Sb Sedan "Zum Schlachten" (Early German Assembly, with a torsion bar spring for the bonnet) - Stored in Country WA
1981 Subaru Brumby 1.8 with Weber and 5-speed box "little utie" - Sold to another enthusiast!
2006 Ford Focus "missus car"
2002 VW Passat V6 30V Station Wagon (my new commuter bus)

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sf0999
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Joined: Sun 30 Aug, 2009 9:40 pm
Model you own: w111
Location: Windsor, Sydney

Re: drum to disc conversion

Post by sf0999 » Tue 29 Aug, 2017 8:25 pm

Bart -yes I do have an inline booster, but it is all part of the single circuit brakes -I need a split system. Not sure what I was thinking when I typed "booster on the firewall", it is the single brake m/cyl on the firewall. Perhaps I was just being optimistic.

Mercmad, thanks -I'll chase up PBR. From what I can see they do not have any boosters with a dual circuit cylinder. It has been suggested that I'll need to run 2 boosters (one for each circuit).

Looks like the handbrake cables are shorter for the rear discs, so I'll have to get those adapted.
W111 1961 220S Classic Rally Car "Eugen"
W126 1988 300SEL "Frankie"

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Mercmad
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Re: drum to disc conversion

Post by Mercmad » Wed 30 Aug, 2017 11:01 am

You can use the same cables or get the drum cables swapped over . How much too short are vthey?

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sf0999
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Re: drum to disc conversion

Post by sf0999 » Wed 30 Aug, 2017 11:58 am

About 5cm short. I have not checked the adjuster to see how much more travel is available -maybe my old cables were that stretched?
W111 1961 220S Classic Rally Car "Eugen"
W126 1988 300SEL "Frankie"

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Bartman4800
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Re: drum to disc conversion

Post by Bartman4800 » Wed 30 Aug, 2017 2:14 pm

Steve,

Can't you use the setup from the later coupe versions?

From what I can see they have a dual circuit master (72 euro's)
The booster is a bit dearer at 600+ euro

http://www.dbdepot.de/index.php?nav=4&lan=1&

All the rest is tubing which is easy. Make sure you get metric nipples from your local brake specialist or PBR


Bart
1963 220 Sb Sedan "Kermit" (Australian Assembly)
1960 220 Sb Sedan "Zum Schlachten" (Early German Assembly, with a torsion bar spring for the bonnet) - Stored in Country WA
1981 Subaru Brumby 1.8 with Weber and 5-speed box "little utie" - Sold to another enthusiast!
2006 Ford Focus "missus car"
2002 VW Passat V6 30V Station Wagon (my new commuter bus)

User avatar
sf0999
250s
Posts: 255
Joined: Sun 30 Aug, 2009 9:40 pm
Model you own: w111
Location: Windsor, Sydney

Re: drum to disc conversion

Post by sf0999 » Wed 30 Aug, 2017 6:44 pm

Thanks Bart, the clutch is the issue. On the early Finnie the clutch master is right beside the brake master. Too close for a booster, hence the inline booster. On the later models (with a conventional booster) the clutch master was mounted under the dash in the cabin. So I'm leaning towards finding another clutch pedal and mcyl. Not impossible, but just another complication to deal with.

Steve
W111 1961 220S Classic Rally Car "Eugen"
W126 1988 300SEL "Frankie"

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Mercmad
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Re: drum to disc conversion

Post by Mercmad » Thu 31 Aug, 2017 8:39 pm

I just had to have a poke around the spares department ( or the pile of faeces as everyone else calls it) and i found a finny manual clutch pedal with master cylinder . This type uses a hose to the brake reservoir to supply it with fluid .Let me know if you want it.
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sf0999
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Re: drum to disc conversion

Post by sf0999 » Thu 31 Aug, 2017 9:00 pm

You're a legend. PM sent.
W111 1961 220S Classic Rally Car "Eugen"
W126 1988 300SEL "Frankie"

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sf0999
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Posts: 255
Joined: Sun 30 Aug, 2009 9:40 pm
Model you own: w111
Location: Windsor, Sydney

Re: drum to disc conversion

Post by sf0999 » Sun 17 Sep, 2017 4:04 pm

Booster issues. There are a couple of threads on W111 boosters, but I'm still challenged to find a solution for mine. I have a later tandem m/cyl, and also an ATE T51 booster (9 inch), however it does not psychically fit -my thoughts are that I need a smaller diameter and also shorter to clear the air cleaner.

So, is there a smaller booster than the T51 (8 inch?), and if so does anyone have one, or know what part number I'm chasing?

Cheers

Steve
W111 1961 220S Classic Rally Car "Eugen"
W126 1988 300SEL "Frankie"

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Mercmad
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Re: drum to disc conversion

Post by Mercmad » Wed 20 Sep, 2017 8:08 am

I have a smaller version here , but it has been sitting for a long time so it should be overhauled before use .

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