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 KLUGEWERKS Disc Brake Conversion Kit Updates 
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Joined: Thu Oct 06, 2011 4:25 pm
Posts: 788
Location: Mount Vernon WA USA
Post KLUGEWERKS Disc Brake Conversion Kit Updates
The disc brake conversion kits have been shipping and four additional trucks are currently in process. Andre at Fat Fabrications is doing three of them and has seen the system first hand and tested its performance personally. We will post photos of the trucks as they are completed.

The website for KLUGEWERKS ("klu-ga-verks" - which means "clever workshop" in German BTW) has been updated with the latest information - http://www.klugewerks.com

I was able to test fit and test drive the disc brake system with a set of Ford Transit wheels - they work very well. Due to their slightly lower backspacing and slightly greater 6.5 inch width (compared to the 6 inch width of the Sprinter wheels), the wheels are moved outward just under 2 inches (50mm) on each side (compared to 29mm or about 1-3/16" for the Sprinter wheels). This results in the wheel's extending 3/4" past the wood rub rails on the sides (with the Sprinter wheels the edge of the tire is even with the wood rub rails). The steering effort and handling both on road and off-road was found to be very acceptable with the Ford Transit wheels.

Attachment:
Pinz side transit sprinter  wheel.jpg
Pinz side transit sprinter wheel.jpg [ 666.01 KiB | Viewed 280 times ]


The pricing on the basic kit has been changed to include the wheel spacers which are required and is now priced "per axle" instead of "per wheel" to make it easier to order. The pricing on the complete kits is still TBD depending on a number of options and the condition of the existing brake system.

Attachment:
Front Discs - small.jpg
Front Discs - small.jpg [ 467.89 KiB | Viewed 280 times ]


Please feel free to contact me with any questions.

Cheers,

Haf-e / Christopher


Last edited by Haf-e on Tue Feb 13, 2018 12:08 pm, edited 3 times in total.



Sat Feb 10, 2018 10:57 pm
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Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
Love it, and the look of the wheels!

Did you guys test hard or emergency braking any? I was wondering about brake proportioning, front to rear. The Gwagens have a proportioning valve and actuator arm on the rear axle that lessons the rear's braking percentage as the little arm changes its angle the more the rear suspension increases distance to the body.

I'm sure anything is far better than those drums.

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Sun Feb 11, 2018 3:01 am
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Joined: Wed Feb 01, 2012 11:39 am
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Location: Ontario, Canada
Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
Kits comes with a Wilwood adjustable proportioning valve so you can fine tune it F to R
Really well designed and complete solution

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Sun Feb 11, 2018 8:42 am
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Joined: Thu Oct 06, 2011 4:25 pm
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Location: Mount Vernon WA USA
Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
So which wheels do you like the look of better?

Hard for me to say with the different colors - I originally thought the sprinter wheels were the best looking (especially with the PUCH center caps) but the transit wheels look great too - the wider bolt pattern looks right on the air cooled pinz to me...


Sun Feb 11, 2018 11:03 am
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Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
That raises the question of how to adjust it? I'd think that loading the Pinz down like you'd most likely have it equipped, would be really important when setting it up. A loaded down bed or trailer tongue with some decent hitch weight would cause the need for very different proportioning than an unloaded rig with only a driver.

I like the front wheels more in the pic. The rears almost look fragile with the amount of holes it has. I know they aren't but it just feels that way at a glance.

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Sun Feb 11, 2018 9:28 pm
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Joined: Thu Oct 06, 2011 4:25 pm
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Location: Mount Vernon WA USA
Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
Yes - the look of the Transit wheels has grown on me - especially when they are painted green to match the truck. Here is a picture of one like that:

Attachment:
Pinz Transit Wheels Brady.jpg
Pinz Transit Wheels Brady.jpg [ 307.49 KiB | Viewed 202 times ]


Yes - the manual proportioning valve does require adjustment when loads vary - its not a perfect solution but it does allow dialing in the amount for different vehicles - for my Pinz which has been mostly lightly loaded I've kept it on the minimum value and the rear end barely locks up on gravel - and only when the front wheels are also locked up. Before I installed the proportioning valve there was way to much rear braking going on... of course when 4WD is engaged then the rear and front axles all rotate together so it's not as much of an issue off-road.

Since the front brakes have dual calipers - and the rear have single calipers (all the same piston size) - the braking is biased towards the front axle by a 2:1 ratio inherently - this is the same approach Steyr-Puch used on the 716 and 718 Pinzgauers.

I did consider the automatic "inertial" proportioning valve used on the late 70s VW bus and Vanagon - it uses a steel ball which rolls up an inclined barrel - so it responds to the vehicle's position (going up hill / going downhill / braking hard front end dive) but they are hard to find quality reproductions (at least that is what I hear from VW guys) and they are much more expensive than the manual valve - about $300 or so... It's almost is a type of rudimentary anti-lock braking system for the rear axle. The british Mini's and Moke's had a similar system but it cut out all braking of the rear axle when the nose dives down - the VW one simple goes from full braking to partial braking of the rear axle.

My Sprinter has the same load / nose dive sensing valve connected to the rear axle - that same system was also added to the 710 Pinzgauers that were rebuilt and upgraded by the Austrian military - they did not add them to the 712 Pinzgauers... I would still recommend a manual proportioning valve as a minimum though on a 712.

In many ways - the same issue exists for the drum brakes - the front / rear braking bias is fixed at a compromise level which is appropriate only for some operating condition - probably with the vehicle lightly loaded... with the manual adjustment you at least can increase the rear braking effect for times when you are heavily loaded and need all the extra braking ability possible.


Last edited by Haf-e on Tue Feb 13, 2018 12:58 pm, edited 1 time in total.



Sun Feb 11, 2018 10:36 pm
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Joined: Thu Oct 06, 2011 4:25 pm
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Location: Mount Vernon WA USA
Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
VinceAtReal4x4s wrote:
I like the front <Transit> wheels more in the pic. The rears <Sprinter> almost look fragile with the amount of holes it has. I know they aren't but it just feels that way at a glance.


Here is a picture of the Sprinter wheels from an angle - they look better that way then when viewed straight on IMHO.

Attachment:
Pinz with Sprinter wheels.jpg
Pinz with Sprinter wheels.jpg [ 204.19 KiB | Viewed 146 times ]


The gross rear axle weight (GAWR) rating on the Sprinter with these single wheels is over 4000 lbs - so they should handle the weight of a 710 or 712 without issue. The Transit wheels are heavier - 32 lbs - vs 30 lbs for the Sprinter wheels.


Tue Feb 13, 2018 11:39 am
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Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
I don't know... the transit in alloy powder-coat might beat them out, for me.

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Tue Feb 13, 2018 12:55 pm
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Location: Boston MA
Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
Here are my disc brake brackets after I had them yellow zinc coated and a shot of the disc and spacer with studs!
Can't wait to get started on the install!!!!


Attachments:
20180214_054252-1612x1209.jpg
20180214_054252-1612x1209.jpg [ 485.97 KiB | Viewed 69 times ]
20180212_171551-1612x1209.jpg
20180212_171551-1612x1209.jpg [ 464.66 KiB | Viewed 69 times ]
Fri Feb 16, 2018 12:31 pm
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Joined: Wed Sep 30, 2015 5:03 pm
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Location: Boston MA
Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
That's my pinz with the transit wheels on them and the beer cans lined up on it...
This was last summer with the drum brakes still on it.
The rims came in black.... I just found some rattle can paint which was a close flat green match....
As they get love marks... I just touch up spray them!


Fri Feb 16, 2018 12:36 pm
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Joined: Wed Feb 01, 2012 11:39 am
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Location: Ontario, Canada
Post Re: KLUGEWERKS Disc Brake Conversion Kit Updates
Yellow zinc looks great!

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Fri Feb 16, 2018 4:59 pm
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