Cooz93 66 Posted February 15, 2015 Report Share Posted February 15, 2015 (edited) Thought I'd do a write up for a 256mm conversion as I've just done one to my mk3 and finding answers wasn't the easiest. What you'll need.256mm brake set up. Discs, pads, carrier, calliper. Probably from a mk4 golf.Polo 9n stub axles - PN 6Q0 501 117Polo 9n rear hubs - PN 6Q0 598 611Banjo type brake linesNext part, you can either saw off the axle spacers from a polo 9n like I did, pictures below, with the rough edge milled flat.Or you can buy lupo gti axle spacers. P/N are 6E0501465A for left and 6E0501466A for right. You'll will also need longer stub axle bolts and longer calliper carrier bolts. Both need to be about 10mm longer.First off remove the current set up, including callipers, carriers, disks etc etc. you'll be left with nothing mounted to the rear beam.Attach the polo 9n stub axle to the rear beam with the spacer in between..It's an idea to bore out the holes on the spacers to the bolts don't pick up on the spacer thread and stop you getting a proper fit to the beam.Mount up the hub and disk to the stub axle..And then mount the new 256mm carrier. From what I've heard, if the brake set up is from a 4motion, you will need a small spacer between carrier and axle spacer like I have. I can't comment on the non 4motion set up!Either way, this is how it will look with carrier and spacer attached..I've used washers here for a quick fix, but for a permanent solution a spacer plate should be made up. The calliper will then mount in the same way the originals did.. This picture was also taken before I drilled out the holes so the spacer wasn't flush with the rear beam, hence why the carrier looks so closed to the disc..And now the set up is complete. Thought I'd finish this off for people using abs.First, you'll need to cut a 'V' into the polo 9N stub axle, where the original abs sensor will fit. After this, you'll need to weld a small bit of pipe into this channel to hold the abs sensor.. Picture below. Be careful with spacing. I used a 0.8 or 1mm shim on the abs sensor to make sure the gap was correct To make the original mk3 abs ring fit, you will need so shim it out. I done this by making a ring to fit over the polo 9N hub, about 2/2.5mm thick. When this is in place the abs ring should be a nice snug fit. Make sure you clean all parts before measuring, as my first attempt ended in failure.. Picture of shim under abs ring..If anyone has any picture request/help/further input feel free to comment.Cheers:) Edited April 16, 2015 by Cooz93 Cooz93, Russvrt, michael5556 and 1 other 4 Link to post Share on other sites
Russvrt 85 Posted February 16, 2015 Report Share Posted February 16, 2015 I think il be doing this soon also..Does this widen the track at all? Link to post Share on other sites
Cooz93 66 Posted February 16, 2015 Author Report Share Posted February 16, 2015 I think il be doing this soon also..Does this widen the track at all?I'm not too sure mate. I guess it will due to the spacer plate but unsure how the two stub shafts compare. I'll mock old and new up tomorrow and have a measure! Link to post Share on other sites
Russvrt 85 Posted February 19, 2015 Report Share Posted February 19, 2015 How you doing with this ,,I have a full mk4 anni rear beam with 256mm vented brakes on and am just thinking about cutting the mounting section off the mk4 beam and welding it in place of the vr mounting point ,...any reason this won't work? Link to post Share on other sites
Cooz93 66 Posted February 19, 2015 Author Report Share Posted February 19, 2015 By mounting section do you mean something similar to what I did with the polo 9n beam? Chuck up some pictures mate might shed some light:) Link to post Share on other sites
Russvrt 85 Posted February 19, 2015 Report Share Posted February 19, 2015 I will do once I start on it ,basically cut the end of the mk4 beam off and weld it on the vr beam. Link to post Share on other sites
Cooz93 66 Posted February 20, 2015 Author Report Share Posted February 20, 2015 I will do once I start on it ,basically cut the end of the mk4 beam off and weld it on the vr beam.As long as you get the angles bang on when you weld it back together there shouldn't be a problem. You may or may not have an issue with the abs. I have a feeling the mk4 works on a similar setup to the mk3 but as I haven't seen both I couldn't tell. I do believe the both use 'cages' for abs detection unlike the polo which uses the Bosch system and has the abs built in the back of the hub. A problem which I hope to figure out this weekend. Keep us updated with what you find mate:) Link to post Share on other sites
Russvrt 85 Posted February 21, 2015 Report Share Posted February 21, 2015 I deleted my abs so don't have to worry about that ..until I see the mounting face on the mk4 axle (still on the car in mates garage) I'm just guessing really.. Link to post Share on other sites
Cooz93 66 Posted April 16, 2015 Author Report Share Posted April 16, 2015 Updated to show abs set up.. Link to post Share on other sites
Cooz93 66 Posted June 2, 2015 Author Report Share Posted June 2, 2015 Set up complete and fitted..Any questions drop me a pm and I'll do my best to help:) Link to post Share on other sites
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