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Showstopper - Technical Article - Chevy High Performance Magazine

Adding a Master Power Disc Brake Kit
From the February, 2009 issue of Chevy High Performance
By Bob Mehlhoff
Disc Brakes Master Power Disc Brakes
The kit we selected for the... 
   
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Disc Brakes Master Power Disc Brakes
The kit we selected for the front of our '65 Biscayne came complete with new disc brake rotors, calipers, adapter brackets, a power brake booster, the master cylinder, including the combination valve with new steel lines, wheel bearings, and hoses.
Disc Brakes 1965 Chevy Biscayne
The stock drum brake setup... 
   
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Disc Brakes 1965 Chevy Biscayne
The stock drum brake setup didn't stop our 2-ton big-block-powered B-body very well. The addition of disc brakes will be a welcome relief, especially during unexpected brake-test sessions.
Disc Brakes Drum Brake
The stock drum brake hardware,... 
   
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Disc Brakes Drum Brake
The stock drum brake hardware, hubs, and backing plates were easily removed. Before we started our install, we measured the wheel-mounting height location on the drum brake hub and compared it to that of the new disc brake hub. We found that the disc brake wheel-mounting position widens the front wheel track 1 inch on each side. To compensate for this, you may want to install the appropriate wheel or tire size to complement the disc brakes and to ensure your tires won't rub.
Disc Brakes Unbolting Drum Brakes
Next we unbolted the drum... 
   
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Disc Brakes Unbolting Drum Brakes
Next we unbolted the drum brake backing plates from the spindles and disconnected the stock hoses from the steel lines.
Disc Brakes Caliper Brackets
Then we attached the two front... 
   
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Disc Brakes Caliper Brackets
Then we attached the two front brake caliper brackets...
Disc Brakes Brake Caliper Bracket
...and found the larger bracket... 
   
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Disc Brakes Brake Caliper Bracket
...and found the larger bracket required the lower inside mounting hole to be reamed out slightly (shown left; original-size hole on right) to allow the bracket to clearance the spindle on its forward lower side. The entire operation took roughly 15 minutes for both brackets.
Disc Brakes Spindle
Finally we tightened everything... 
   
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Disc Brakes Spindle
Finally we tightened everything in place. Double-check the directions to ensure proper torque is applied onto all bolts and nuts.
Disc Brakes Fitting Brake Rotor
The new brake rotor is then... 
   
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Disc Brakes Fitting Brake Rotor
The new brake rotor is then fitted with new wheel bearings, which we packed with grease, followed by a new inner seal. After the rotor is installed onto the spindle, we spun the rotor while tightening the spindle nut several times. We then backed off the nut just to the next available slot and installed a new cotter key and grease cap. When the rotor is installed properly, there should be a very small amount of endplay felt when the rotor is pushed and pulled laterally on the vehicle.
Disc Brakes Brake Hoses
Next we loaded the front calipers... 
   
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Disc Brakes Brake Hoses
Next we loaded the front calipers with the new brake pads, slipped them into position, slid the caliper over the rotor onto the mounting holes, and bolted them in place. From there we installed the new brake hoses with the appropriate copper washers.
Disc Brakes Clearance Inspection
Before we installed the front... 
   
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Disc Brakes Clearance Inspection
Before we installed the front wheels, we made one final inspection for clearance, rotor rotation, and did a once-over on the brake-line installation.
Disc Brakes Tire Clearance
We then remounted the front... 
   
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Disc Brakes Tire Clearance
We then remounted the front wheels and put the car back on the ground. Remember that with the new rotors in place, the wheel mounting positions are moved out 1 inch per side. So make sure you'll have enough tire to fender clearance with the car settled on the ground. If not, different-size tires or rims will give you the necessary clearance.
Disc Brakes Master Cylinder
Our front disc brake kit came... 
   
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Disc Brakes Master Cylinder
Our front disc brake kit came with a power brake unit, master cylinder, combination valve, fittings, and metal lines. Since less vacuum will cause a hard pedal, your engine should ideally be able to produce 18 inches of manifold vacuum at idle in Park. Anything less, and you may want to opt for the manual disc kit or install an electric vacuum pump, which is also available from MPB.
Disc Brakes Stock Master Cylinder
We first removed the stock... 
   
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Disc Brakes Stock Master Cylinder
We first removed the stock single reservoir master, metal line, and power brake booster.
Disc Brakes Stock Clevis
Then we disconnected the stock... 
   
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Disc Brakes Stock Clevis
Then we disconnected the stock clevis from the brake pedal and drilled a 3/8-inch hole 1 inch below the original.

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