Brake Swap using complete donor quad

Discussion in 'Brakes' started by FakeName, Nov 23, 2018.

  1. FakeName

    FakeName Member

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    I was in the market for a clean, original 03+ Blaster when I found a clean 91 model. I went ahead and bought it, with the intention to find an 03+ to buy as a donor for it's brakes. I wanted to have a complete quad on hand to make sure the swap goes smoothly.


    However, I have started reading up on this and have found some conflicting information. The front seems straight forward enough. Swap out spindles, hubs, and brake components. Looks like the A-arms for the older and newer models are identical so this should be a painless direct swap.


    The rear looks like it may cause some problems. I know I would of course need to swap axles and brake components, but I did read somewhere that the frame itself is different between pre 02 and post 03 models. Any truth to this? If so, what is the difference?


    I would like to keep the frame on my 91 because it is in near perfect shape and I have a clean title for it.


    If I find a good donor, will I be able to do the swap as a bolt-on affair?


    Thanks
     
  2. Awk08

    Awk08 Moderator Staff Member Technician Forum Supporter

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    the differences between the pre 03 cable brake models, and 03+ hydro models are the pre 03 models ....

    frame missing mounts for master cylinder and resivior
    foot peg has a more forward barrel for the brake pedal to mount, 03 pedal will not work on pre 03 peg.
    brake pedal lacks extension to actuate the master cylinder
    carrier mounts incorrect for hydro caliper
    axle splines hold the floating disc out further

    to successfully mount hydros on a pre 03 model requires:
    an 03+ peg and pedal, or extension welded to pre 03 pedal
    mount for master welded or bolted to frame to hold master in an exact location for proper pedal to master action
    mount for resivior
    a complete 03+ axle/carrier/disc
     
  3. FakeName

    FakeName Member

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    Thanks for the info. If I had a complete donor it sounds like my only issue would be the missing tabs for s master cylinder. I could swap pegs, pedal, axle carrier, etc.

    I have read several references to a kit you used to make, but don’t have available any longer. Did that kit use a master cylinder bracket that jolted on or did it require fab work?
     
  4. Awk08

    Awk08 Moderator Staff Member Technician Forum Supporter

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    a fabbed bracket to bolt on to the pre 03 frames with an extension welded to the existing pedals
    it wasn't perfect as the throw of the pedal was very short, but they bolted on in 20 minutes and worked every time with very little foot pressure.


    [​IMG]
     
  5. FakeName

    FakeName Member

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    I’ll have to look into maybe finding one of your kits or study it and make something similar. I want to avoid welding onto the frame. Would rather bolt on something on the event i ever want to return it to factory. I’m not the best welder and don’t want to butcher my otherwise pristine frame.
     
  6. FakeName

    FakeName Member

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    I’ll have to look into maybe finding one of your kits or study it and make something similar. I want to avoid welding onto the frame. Would rather bolt on something on the event i ever want to return it to factory. I’m not the best welder and don’t want to butcher my otherwise pristine frame.
     
  7. Larry's Shee

    Larry's Shee Active Member

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    If you get a dinner why not just swap frames ?
     

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