I started looking for bigger brakes for my GT when I decided to tune my engine. I noticed directly that there where many solutions bolt on for sale but sadly not for a price I thought was reasonable for the stopping power you got. Living in Sweden made me off course look first at Volvo parts and I directly noticed that the 4 pot calipers from the 240 series basically just bolt on. The problem was to find a suitable disk however.

Volvo uses with this claws 262,5x22mm disks and I wanted disks that where as big as possible to avoid the pads sticking outside the disks. The Volvo disks where unusable because of the completely wrong height of the disk.

The height I wanted was 53mm , my GT had original 55mm disk height but because of the Volvo caliper's slit for the disk being in a somewhat different position compared to the original caliper I ended up on 53mm. After unlimited trips to local parts shops and a few all-nighters on the net I eventually ended up with Honda disks. They are 262x21mm and a height of 51mm and have a 4 hole pattern for the wheel bolts. These disks are used on the Prelude 2.0i 16v 87-91. Honda used them on more cars but of this one I' am sure. Well 51mm height instead of the needed 53 mm was not such a problem because the Volvo calipers are so thick and strong that it was no problem whatsoever to machine away 2 mm from the surface of the caliper where it will be connected to the car.

Now all what was left to do was machine up the center hole of the disk and to drill 4 new holes so I could bolt the disk on to the original Opel hub.

I also wanted new dustcovers, because the original ones became to small with these new disks. I looked at several models and brands that I thought I might be able to alter to fit on an Opel. When I noticed this was not going to work, they all seemed to disagree with the steering knuckle, I designed some myself. I had them made out of billet high quality aluminum that was then black anodized.

On the pictures I' am using Tarox G88 special disks and EBC green stuff pads. The special disks , pads and custom made dustcovers made this brake conversion expensive but still more than 100€ cheaper than what you would pay at a tuner for a set of 246mm brakes. The special disks where not completely necessary but I could recommend the pads, they are great.

A few things to keep in mind:

Use the Volvo 240 series Girling brakes for ventilated disks Not the ATE ones these where used with thicker disks. All the measurements I give here are based on the GT , I' am not sure if it's completely the same on other old opels. These brakes don't fit in original 13" rims. They do fit in 14" steel and 15" alloy wheels and maybe in some kinds of 14" alloy wheels-

If you have any more questions or are interested in the dustcovers, feel free to mail me at Opelgt69@hotmail.com

Koen