FCP Groton 302mm brake upgrade WILL fit Columbas, Part 1

Post by **Nevada1906** » 02 Jun 2012, 14:53

After asking around on this site, I decided to go ahead and upgrade my brakes. After researching the topic, I decided that I could make the FCP Groton 302mm kit fit my car and its 16" Columbas. The sources that say this size brake doesn't fit Columbas are correct, but they usually fail to elaborate that if you're willing to modify the calipers. you can have the big brakes. Here's how I did it.

Starting with this:

: 001: Here's what I started with: FCP's 302 Upgrade kit.

The trick is to shave the caliper ribs off COMPLETELY to get a smooth, constant curvature devoid of any projections. Use a grinder. Just trust me.

: 002: The view from the outboard side. Note that the ribs are gone and the curvature is smooth and constant all the way across the caliper.

Again, curvature from back side of caliper.

: 003: Here's the inboard side. Again, note the smooth, regular curvature.

New rotor and bracket fitted to front spindle. Pretty.

: 004: New 302mm rotor and caliper bracket, with black engine block paint drying.

The calipers are now nice and smooth on top (front, I guess).

: 005: Same engine paint. Shiny.

Rear brakes. I replaced all the emergency brake hardware while I was at it.

: 006: Rear brakes. No modification necessary.

New stainless steel rear hose.

: 007: New hose. I love the contrast of old and new.

And finally, the wheels that necessitated all this. I still like 'em, though.

: 008: Cleaned these up nicely.

Let me tell you though, I hurled a whole soccer riot's worth of invective and profanity at the car while I was doing this conversion. You only end up with about 2 mm of clearance between the caliper and the inner surface of the wheel, but it's still clearance.

I'm waiting for the paint to dry right now, so when I get it back together, bled out and tested, I'll post Part 2.

Should be in a day or two.

Post by **matthew1** » 02 Jun 2012, 18:37

Outstanding. I've got Columbas and a set of 302's waiting to go on and was going to go the grind route, but you beat me to it. Just the fronts for me.

Going in the Repair Database.

Post by **BEJinFbk** » 02 Jun 2012, 19:42

Hey, Matt - It would be cool to see before and after pics of that caliper mod.
I'm sure this write up will make a lot of people happy - Have fun!

Post by **Nevada1906** » 02 Jun 2012, 20:17

Yeah, I know I didn't take any Before shots, but I'm not normally one to document operations. The urge just sort of hit me after I had painted the calipers. I'm regretting that choice right now.

I should point out to anyone who decides to pull the trigger on this conversion that there is a fair amount of Grind Caliper-Mount Caliper-Mount Wheel-Check Clearance-Dismount Wheel-Grind Caliper Some More-Lather-Rinse-Repeat involved.

It'll be tight, but the Columba WILL clear. Notice in the stock shot the below, the external ribs stand proud of the surface about 3/16 inch.

: 8111101.jpg (46.23 KiB) Viewed 4005 times

Knock them down all the way to the main surface.

I used Rust-Oleum Engine Primer and Enamel here.

MilehighV70XC · Post by **MilehighV70XC** » 03 Jun 2012, 10:27

Maybe it is just me, but that does not look safe. We are talking about the most important safety feature on the car.
The "ribs" look to be there for added strength for the flat section spanning the pads. As the piston pushes against the pads, it seems to me where the ribs are would be a high stress area. That's why I think they where designed with extra material there. What you grind off kind of looks like it acts as a structural brace for the outside pad area. Everything will probably work just fine, but just some food for thought

Post by **Nevada1906** » 03 Jun 2012, 13:08

Oh good Lord...that attitude is why we don't have working fusion reactors yet.

To paraphrase Morpheus: "What is Safe? How do you define Safe?"

Personally, I think safety is a matter of perspective. Sure, I'm up on the roof without a fall harness, but no one's shooting at me.

But I guess we'll see, 'cause it's too late now!

Post by **matthew1** » 03 Jun 2012, 13:16

BEJinFbk wrote:Hey, Matt - It would be cool to see before and after pics of that caliper mod.
I'm sure this write up will make a lot of people happy - Have fun!

Yea, I'll document it beginning to end.

I thought about another wheel to fit the 302mm's, but I can't do it. I have a purist streak -- there's something "perfect" about a car looking the way it came from the factory, calipers and lowering excluded.

I notice immediately when a Volvo newer than say mid-1970s has a Volvo wheel on it that was not paired with that model. I thought about Perfos to fit the 302mm's, but I'd rather go aftermarket wheel than mismatch Volvo car / Volvo wheel. I find some aftermarkets to look great on Volvos. Bronxnative's wheels come to mind, wish I had a pic of his 850 N/A manual.

Not to say my 850 is perfect, far from it, unfortunately. But I digress. Getting off topic and preachy.

MilehighV70XC · Post by **MilehighV70XC** » 03 Jun 2012, 17:07

Hey Nevada1906, I was just adding something to the discussion, no attitude here.That's why I said "it will probably work just fine'. What do I consider safe? Pressing on the brake pedal and knowing the caliper with function properly. I am all for people trying and testing new mods. That's what being a car enthusiast is all about. No need for the attitude. This it what a discussion forum is for. To discuss thing like this and hear other peoples point of view and opinion.
Your analogy comparing the two if pretty far fetched. Been on plenty of roofs with no harness. Would I go on a highrise with my family with no harness, NO WAY, but it is your car and your family in it, so best of luck. I do hope it works out, I always like big brake upgrades

Post by **BEJinFbk** » 03 Jun 2012, 18:13

matthew1 wrote: I thought about another wheel to fit the 302mm's, but I can't do it. I have a purist streak -- there's something "perfect" about a car looking the way it came from the factory, calipers and lowering excluded.

You could always look for a set of the '98 V70R's 17" cousin, the Comet.
Metoers and Comets look an awful lot like Columbas...Just a thought.

Regarding the caliper shaving safety comments - The more I think about it,
the more I have to agree about erring on the side of safety and going with 17's.
I can only imagine how much fun it would be to have a large and jagged chunk
of caliper spinning around inside of one of my steering rims at speed.
Sure, it'd be a cool story, but thinking it through...I'd pony up and go 17's.

Post by **Nevada1906** » 03 Jun 2012, 18:35

- ENGAGING RANTSPLANATION -

MilehighV70XC,

I was just trying to say that I'm not a fan of the modern philosophy of Safety (whatever that is). What I heard in your comment sounded like Marge Simpson whining about What Ifs. That's why I said what I did. I'm not actually trying to offend anyone. Who knows, you might have less regard for Safety (whatever that is) than I do. And if so, I salute you!

The bit about the fall harness isn't far-fetched at all; it's a little saying I use to illustrate the point that though a particular activity or operation might look or seem hazardous to one person, it might not be perceived as unsafe by the person actually involved in said operation, for whatever reason. I'm doing one type of risky thing, but it's balanced out by the fact that I'm not participating in some other risky thing.

To me, the modern concept of Safety is properly identified as Paranoia. It's not the management of risk, but rather the attempt to eliminate risk. It's not a cost-benefit analysis, but rather a nail-biting What If. It's preventing valuable technological advance and the betterment of mankind in the name of The Children or Safety or whatever else the fearful are using as a pretense. Note that I'm not saying you're one of these.

Can I guarantee this conversion will work? No, but I'll try it anyway. Maybe there's a risk, but to me it seems an academic one, and if I'm right, I've gained a new capability for my vehicle. All the numbers add up on paper, so I'll go ahead. I think these brakes will operate properly from here on out, but if not, I'll deal with it.

It's the same problem with the manual swap. Maybe Volvo never built the US-space turbo cars with five-speeds, but that doesn't mean we're cursed to wander in the wasteland with the computer shifting for us. This brake upgrade is just a variant of that situation.

I'm no fan of physical pain. I hate It. But the thought of not trying something that will most likely work in my favor hurts more. And the idea of using someone else's cost-benefit analysis to make my decision burns me.

- DISENGAGING RANTSPLANATION -