Alternative rear disc conversion?

[Neinris]

I was hoping to drop this comment yesterday to commemorate the two year start date of this project, but I got too busy.

Anyway, I know there's other threads out there that discusses what parts are required, etc., here's my version of what's required:

Rear disc conversion
Parts required:
Yaris SE parking brake cables (right) 4643052360 (left) 4642052370 [will require swapping hangers if not the same GEN Yaris]
Yaris SE rear axle beam 4210152160 or adaptor plates made
Yaris SE hard brake lines (right) 4732352110 (left) 4732452100
Brake hose retaining clips (2) 9046808035
Yaris SE brake hoses (2) 9094702E11
Brake dust shield (right) 4780352030 (left) 4780452030 [optional]
Yaris SE rear rotors (2) 4243152080
Toyota hub bearing mounting bolts (8) 90119A0350 [longer w/ washer (cut the washers out), not required if doing axle swap]
Yaris caliper carriers/bracket (2) 4782112151
Disc brake caliper pins (4) 4783512150
Bush dust boots (4) 4787512150
Caliper bracket mounting bolts (4) 91552C1035 [require washers if using adaptor plate vise axle swap]
Yaris Calipers (right) 4783052161 (left) 4785052161
Caliper mounting bolts (4) 90012AA102
Yaris SE rear brake pads (set) 0446652170
Yaris SE rear brake pads shim kit (set) 0494652080
Yaris SE rear brake pads anti-rattle clips (set) 0194812060
Toyota brake caliper banjo bolts (2) 90401A0001
Toyota caliper copper crush rings (4) 4738950020
Brake fluid of your choice
Note, these are all Toyota part numbers (according to parts.toyota.com), which are expensive. Aftermarket can be found for much cheaper and sometimes much complete where you don’t have to buy them piece by piece. I used a combination of RockAuto.com and EBay to get my parts. I was in no rush to get them, I did this over time when I have a little bit of money for myself, and so my pocket didn’t take too much toll.
Another option is you could go to the junkyard and pull them. If you’re looking for calipers in the junkyard, you could actually grab the 2nd GEN Scion xB’s (xB2) calipers, but use the Corolla rear caliper brackets, the xB2’s caliper brackets extends farther out to accommodate the 279mm diameter rotors, Yaris and Corolla rear rotors are only 259mm. The first pic right below shows the Corolla, xB2, and Yaris' calipers, then the Yaris's caliper over the xB2's caliper, to show that the bracket is extended out.
Corolla vs xB2 vs Yaris calipers.jpg
xB Yaris rear caliper.jpg
Also, I want to say that the Scion xB2 and Prius rear axle beam could probably be used as a replacement for the Yaris SE, but I'm not yet 100% sure at this point. I want to point out that the mounting hole bolt patterns are the same as the Yaris' rear wheel hubs.

If you’re not doing an axle swap, a couple of brackets must be made and welded on the axle beam for the rear most brake hoses that bolts to the calipers (sorry I don't have a picture of how I did this). What I did was mockup the locations by installing the hard lines first, then marked where the spots would be as close as possible to the stock locations. I believe that the brackets that I made are 1.5in (48mm) wide by 2in long (51mm), and 1/16in (1.6mm) thick with ¾in hole (19mm).
For the adaptor plates, I recommend using a ¼ inch or 6mm thick steel plates. The exact dimensions of the ones I used are 6 inch X 6 inch X ¼ inch, this is strong enough, and any thicker would make the center bore dowel not rest into the axle frame, which would make the bolts bear all the weight. In my previous post, I measured the center bore dowel at about 8.15mm. With the ¼ inch steel plate added with the thickness of the slash guard, the thickness is about 6.85mm, that leaves about 1.3mm of protrusion through the back, to rest in the axle beam's hole.
Rear Hub & Adaptor Plate.jpg

My previous calculations were wrong, when I said how much the rear track got wider, I forgot to include the splash guard, which are about .5mm thick. The original drum brake back plates were 2mm thick. So subtract that from 6.85mm, which means the rear got pushed out 4.85mm on each side, making the front still .3mm wider, not 1.3mm like I previously said. I could still be wrong, because I didn't really got to measure the splash guards. All I know is that the wheel hub's center bore dowels still has some protrusion, because they were not sliding off even without any of the bolts in yet.
Maybe when I replace the hubs to the 5X114.3 PCD, I'd hope to remember to take the measurements of the splash guards, then I'll see how much the rear track really got pushed out. Anyway that's another project...

I used the Corolla’s rear hub mounting bolts, since they are longer and I got them from when I initially was going to use the Corolla’s adaptor plate, but they will require cutting out the washers.
Corolla Hub Bolts.jpg

To make the holes and bolt pattern on the adaptor plate, I had the Corolla back plate as a template, but one out of a cardboard can easily be made, I recommend something a bit thicker material.
Start with a 74mm hole, put your wheel hub in it and drill out the mounting holes, I believe they were 12mm if I remember correctly. I bought new wheels hubs, so I used them as a template, so I didn't have to remove the ones out of my Yaris. As you drill one out, put a bolt in it's place so that the hub don't move/swivel and get a more accurate pattern. Leave the hub in place, and fit the rotor. Now mock the caliper with the bracket and mark where the it would mount on to the plate. I don't remember the bolt hole size for the caliper bracket, I think 10mm. Then transfer that to the adaptor plate and Voila!!! Or send me a PM and you can have a pair for $75 plus shipping.
I hope someone finds this useful.

[tayxas]

Originally Posted by Neinris

I was hoping to drop this comment yesterday to commemorate the two year start date of this project, but I got too busy.

Anyway, I know there's other threads out there that discusses what parts are required, etc., here's my version of what's required:

Hey Neinris, glad I found your thread. Are you willing to reproduce a set of those brackets? SE rear beams are rare and pricey. Would rather go this route.

[Neinris]

Originally Posted by tayxas

Hey Neinris, glad I found your thread. Are you willing to reproduce a set of those brackets? SE rear beams are rare and pricey. Would rather go this route.

Greetings Tayxas! My apologies I have not been active here for a bit. Other hobbies are taking over my time. I still have other plans for my Yaris.

Anyway, I'll ask my friend if he'd be willing to make another set if you're still interested.