Nova rear disc conversion

[gte86]

have got my astra gte rear beam sittin in front of me and want to put the discs on my nova beam. is it just a case of changing the stub axle or is there more involved. i noticed that the handbrake runners are differnt, do i have to cut and weld this?
have done a search and couldnt find any info that helped me. any one know a site or a link with a 'how to' guide.
also do i have to fit nova saloon bias valves, and where are these located.

any help much appreciated. Tom

[gte86]

any gen? i need to get it done this weekend.

[Kieran]

Unbolt the hub assemblies off each side of the beam. You'll see a 10mm thick plate welded on each side of the beam that has the Astra stub axle stud pattern drilled in it. You'll have to cut these plates off the Astra beam and weld them on the ends of your Nova beam (after removing the 10mm thick plates off the Nova beam with the Nova stud pattern in). Once the plates are welded on, use the holes as a template to drill the Astra stud pattern in the Nova beam. Then you can just bolt everything in place.

[Kieran]

Almost forgot, the bias valves are screwed into the side of the master cylinder under the bonnet. Ideally, you want the 3/25, 3/27, or 3/30 valves. The lower the second number, the more restrictive they are.

[Benn]

one think i will say,
is people say use differenthand brake guilds,
well done
use the nova ones,and a mk3cav handbrakes cable,

[Chris S]

if u dont fancy cutting the plates off ive got a pair laser cut,
£22 delivered

[DutchNovaDiesel]

Grind off the old plates: (be sure NOT to cut in to the beam itself)



Nice and clean axle, ready for the astra plates:

Difference between nova(left) and astra (right):

Astra plates welded on the nova beam:


You might want to cut some slits in the beam like this (and bend the thin end outwards):

Otherwise the bolts will be very close to the beam (i modded the bolts):

Finished:

On the car with new brake pipes (old ones can be bent to fit...but it is not 100% guaranteed to work, you could snap them wile bending)

'91 Nova long cable, '89 Cav 1.6 short cable extended with a piece of threaded bar (M8)

The bias valves i'm using are the originals mounted on my nova van (3/30)

My advice: source a second rear axle and take your time...

Cheers, J

Complete manual can be found HERE
Manual is written for the complete kit...using astra handbrake cables.

[Benn]

whats that?
is that the hand brake guild?

[DutchNovaDiesel]

Nope, just a picture of grinding the old plate off

[BarryGTE]

excelent write up that mate,this should be put in the how to section