Disc Brake conversion for my 1959 Morris Minor Convertible

By Joe Greene

I wanted to convert my Morris Minor Convertible to disc brakes and after a little research I found that there are many kits out there that vary in quality and price. I choose a Grumpy kit from EMS of England. I am happy with it but went through the ups and downs of any repair/change.

I got the kit and laid it all out on the hood of the car. I proceeded, after reading the instructions, to remove the road wheels, drums all brake parts and hubs.  Then I drilled out the 4….5/16” holes to 3/8”.  Next I installed the backing plates/dust shields and caliper mounting plates and torqued the bolts to suggested amount.  The new hubs and bearings were packed with grease and installed. All went together like a dream.

Next I installed the necessary mounting brackets for the flex hose and was now ready for the first caliper……began to fit the caliper and when I went to tighten it the rotor stopped turning and was bound up!!!!! After a couple hours of investigating, I found that one of the threaded bungs was welded in the caliper mount incorrectly. The bungs were not parallel.  I then compared it to the opposite side and ground off about a 1/16” of an inch so all was square for the caliper to line up properly. Reinstalled it and the rotor was free.

I snugged up the wheel hub nut and moved on to the small metal brake pipe that had to be formed to connect the flex hose to the caliper. Piece of cake. Right side was now done. I was very happy with the install and results.

The left side went so smoothly that it only took me about 2 hours to complete the installation from start to finish!!!!

Next was the master cylinder!!!

Now according to the instructions I am to remove a seal from the master cylinder to work with the new front disc brakes. I went ahead and order a new cylinder not having any idea of the condition of the existing one. I was blown away when I finally located the master cylinder. It is inside the car under the floor board inside the left side frame rail!! A very long story short……. After 3 days….lots of screws to remove the covers inside the interior……..I eventually got the old one removed and with the help of my friend Calvin got it replaced all lines inspected and connected and ready for bleeding.
An hour later we went for a drive and the brakes were a great improvement!!!

Now for the next upgrade……. I am having a 1275 BMC engine built to get it up to speed. That will be in the next article.

With A smile every mile.

Cheers,

Joe