Fronts

Front brakes from a 205 to a 185 are generally difficult to fit so I've been doing a lot of research and was originally going to go with Martins kit but waited for over a month and decided to go another way. The way I have found means:-

[*]you dont need to fit longer wheel studs
[*]you can keep the dust shield
[*]you dont need a spacer behind the dicsc
[*]you dont need to split the caliper
[*]you dont need to mill anything off the caliper
[*]you dont need to redrill the pcd

So, on with the upgrade!
Chock the back wheels and make sure the handbrakes on!
Get the car up in the air and secure with axel stands again.
While I was under there I treated any rust by griding it off and treating it before wayoxyling the arches and floorpan again
Remove the wheel and you are left with this



Same thing as above, remove the flexi line from the caliper first and if you are upgrading you will need to remove the clips etc and get it through the strut as mentioned above. Caliper removed.




The old disc (in my case) is a 277mm disc and the new one is 296 and a tad thicker from a toyota avensis as the offset of the disc fits really well!
Old vs new




A small part of the dust shield has to be cut off to fit the new caliper



I used a hammer to tap the dust shield back a little and as it was rusted I decided to grind off rust, use Kurerust and then paint it up again to make it pretty





I cleaned up the calipers and pushed the calipers back in as I needed them in as far as they could go



Next I needed new nuts and bolts to fit the new caliper as the old caliper was threaded but the 205 isn't. I read that there is a problem with this as it means you cant get the caliper off without splitting it. I put the nut on the inside of the caliper and it clears the disc no problems. The trick to this is to use a 19mm spanner on the inside of the caliper and then another on the outside.





I put the disc on and secured it with two wheel nuts and then started the process of connecting everything up. Everything seems to be a-OK apart from the thinner disc meant that there was a bigger gap on one brake pad than the other.






I measured this up and it was approx 8mm so I need a spacer making up. I bought some mild steel and asked my local shop to make up two spacers from the brake pad as a template.




After getting the spacers back I could finally start putting it all back together as mentioned above. The spacer cleared up the space a LOT better and looked good.



All finished



I haven't been able to do any miles on this yet as the brake pipes are corroded and need replacing so that's up next but I will report back on the performance and if there are any problems.

Hope you liked it and if it is of any use, please let me know!