Today I installed the rotors onto the front wheel hubs and attached the completed hub and rotor assemblies onto the front suspension.
I bought a pair of new Disk Brakes Australia (DBA) rotors from Dean at datsunparts.com for $230. As far as I can tell (and I looked around) DBA is the only company that makes aftermarket rotors for the roadster (#DBA 610) and new rotors are NLA from Nissan. DBA also offers slotted rotors but I went with the plain ones. The new rotors come wrapped in plastic and with a thin coating of oil on the surface, presumably to prevent any surface rusting prior to installation.
The rotors bolt into the backs (insides) of the hubs in four places. I cut-out just a square of material from the top of the packaging that would enable me to access the bolt holes without fully exposing the rotor to the dust, grease, and other debris in my work area.
I used a bit of brake cleaner to wipe off the surface I’d exposed.
I made a similar cutout on the bottom of the rotor to acces the opposite sides of the bolt holes.
I added the hub on top of the rotor. I slide the rotor towards the edge of my workbench so that the bolt holes underneath would be accessible from below. Using an extension and a 5/8″ socket, I fed the first bolt up through the hole in the rotor and into the threaded hole in the hub.
I rotated the rotor and hub 180 degrees and started the bolt on the opposite side of the rotor in the same manner, but threaded it by hand at first.
After getting all four of the hub-rotor bolts started I tigthened them down sequentially around the hub. This ensured that the rotor and hub met parallel and prevented the bolts from binding up. After several passes around the rotor the hub and rotor pulled together.
I flipped the rotor over (now that the risk of the two pieces coming apart was gone) and did some further tightening with the wrench, again moving in sequence around the rotor.
I got the bolts fairly tight by hand.
Then I used my impace wrench to do the final tightening of the four bolts on each rotor and hub.
With the rotors attached to the hubs, I went ahead and packed the outer wheel bearings with grease.
When the grease came out of the bottom of the bearing I knew it was fully packed.
I placed the outer bearing into its race in the hub and placed the spindle washer on top of it.
Next I removed the protetive wrapping from the rotor, wiped it clean using brake parts cleaner, and prepared to place it onto the spindle.
With it on the spindle I rotated the spindle washer until its tab locked into the groove on the bottom of the spindle. Then I began to twise the castled spindle nut onto the spindle.
I tightend the spindle nut usine a 1 1/8″ socket. Then I torqued it down to 35 pound-feet.
Then I backed the nut off 1/8 of one turn.
I added a 1/8″ 2″ cotter pin through the castled spindle nut and bent it around to prevent the spindle nut from ever backing off.
A while ago I bought a pair of new spindle end caps one ebay for around $12. My old ones were pretty scarred-up. I believe these are still available from Nissan.
I added the new cap onto the end of the hub. It took a good smack from the mallet to drive it on flush.
My final step was to clean off the outer surface of the rotor using some brake cleaner and clean paper towels.
Once I put the brakes on this thing will be ready for wheels!