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Suspension, Handling & Brakes Suspension set ups, uprated brakes

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Old 26-04-2005, 01:04 PM   #1
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THE DEFINITE 206 GTi BRAKE CONVERSION GUIDE

ok chaps, got my 206 GTi calipers today to fit to my S2 Rallye.

Several members have done this conversion so I want to gather all the information together and put it into a definite guide for future reference.

I have got the later type Bosch 2 bolt calipers but there are 2 other types of caliper fitted to the 206 GTi....

so first question is what type of calipers have you all got?

wanna know any problems associated with the brake conversion, and any little mods needed.

some FAQ's below, think of anymore just add to this topic

Do you need 106 or 206 brake lines?

Will 106 caliper bolts fit the 206 calipers?

Do you need any other fitting bolts/brackets/screws etc

Will they fit under 14" steelies or do they need anything grinding off?

Ok with 106 master cylinder?

anything else....?
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Old 26-04-2005, 01:06 PM   #2
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the bosch ones that i fitted to russ w's S1 needed the carrier grinding a little to enable the bolt holes to line up... Also there are 2 different disc offsets - one is wrong.
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Old 26-04-2005, 01:10 PM   #3
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I have got the 266mm discs, 20.4mm thick, vented, 27.3mm offset,
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Old 26-04-2005, 01:10 PM   #4
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same offset as S2 rallye ???
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Old 26-04-2005, 01:13 PM   #5
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there are 2 disc offsets for the GTi. 27mm and 34mm. I needed the 34mm ones (which were the same as my 106 discs).

Pretty much as per Matt above too. Use the 106 hoses, and it's recommended you get a 22.2mm master cylinder too from brakesint.co.uk which will help with the pedal travel (mine goes a LONG way before any serious braking happens, but you get used to it)

The 106 caliper bolts are about 3 times too long. You need Part Number 4405 17 which are the correct mounting bolts for the 206 GTi.

Other than the above, go straight on :] No idea what calipers I got, they came off a 206 HDi Turbo (DW10TD) which are apparently the same as GTi ones.
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Old 26-04-2005, 02:02 PM   #6
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Mark I have the same brakes as you fitted to my s1 rallye, which were salvaged from a 2001 206 XSi 1.6 16v.

Do you need 106 or 206 brake lines?
It looked as if both the 106 and 206 pipes would have fitted but I used the 206 ones as they were newer and looked more robust

Will 106 caliper bolts fit the 206 calipers?
no, the bolts for the standard s1 bendix callipers are much too long. I used the 206 bolts.

Do you need any other fitting bolts/brackets/screws etc
no

Will they fit under 14" steelies
yes

Ok with 106 master cylinder?
bit more travel but it never bothers me.

anything else....?
A small part of the carrier must be ground off before they will fit onto the hub properly. 2mins with an angle grinder, and you're off.
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Old 26-04-2005, 02:27 PM   #7
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I have the earliest 206 GTi Bosch calipers, single bolt holding caliper onto carrier from 206s up to Aug 1999. Bought 4 calipers screws from Peugeot for about 10. Fitted straight onto 1995 S1 Rallye struts, no grinding no nothing. Used 106 Goodridge lines. Had to move the weights from inside of steelies as they catch. Using standard 106 master cylinder.

Excellent upgrade for the money. Well pleased.
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Old 26-04-2005, 04:47 PM   #8
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oh i got the 2 bolt calipers btw. needed the larger offset discs.
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Old 26-04-2005, 06:17 PM   #9
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The 206 GTi/HDi calipers changed at 2002

getting good info here, this is what we need in the 206 guide

106 discs offset is 34.5mm

so am I right in thinking the later type 206 calipers (2 bolt) need the 34.5mm offset 206 discs and early 1 bolt calipers need the 27.3mm offset discs??

Or do all calipers need the 34.5mm offset discs?

Ok sounds like either 106 or 206 hoses will fit.....will test them both

master cyllinder? will try and see if it needs it....

keep the info coming....
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Old 26-04-2005, 06:20 PM   #10
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the threads on the 206 and 106 hoses are the same, i used the existing 106 hoses.

2 bolt calipers need 34.5mm offset discs. the 27.3 discs DID NOT WORK. Dont make this same mistake :]
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Old 26-04-2005, 06:24 PM   #11
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S2 caliper bolts lot shorter than S1, still wont fit, you def need 206 one's yeah...will order some in 2moro to compare
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Old 26-04-2005, 06:37 PM   #12
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yup, they're about 1/3rd off the length :]
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Old 26-04-2005, 07:36 PM   #13
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Yeah, the early single-bolt calipers seem to take 27.9mm offset discs. Although I haven't measured mine so can't check until I renew the brakes really.
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Old 26-04-2005, 08:01 PM   #14
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Quote:
Originally Posted by Mankee
Yeah, the early single-bolt calipers seem to take 27.9mm offset discs. Although I haven't measured mine so can't check until I renew the brakes really.
ok just had a look at the calipers and pads. The pads have these little gold clips with them with I presume hold the pads in somehow...

also pads ends are slightly different so need to know which pad goes where, not obvious at the mo with caliper sat on table...

how do the one bolt calipers fit to the strut as there are 2 holes....?
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Old 26-04-2005, 08:04 PM   #15
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nah, single bolt holding caliper to carrier, then there's 2 bolts holding caliper to the strut.

get pics of what you got ? my pads were wrong, they had funny rounded mounts when mine needed square mounts.
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Old 26-04-2005, 08:11 PM   #16
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Quote:
Originally Posted by Russ W
nah, single bolt holding caliper to carrier, then there's 2 bolts holding caliper to the strut.

get pics of what you got ? my pads were wrong, they had funny rounded mounts when mine needed square mounts.
oh I'm with you now! re 1 or 2 bolt - this decribes the carriers to caliper not caliper to strut.

yeah will post some pics up asap...
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Old 26-04-2005, 08:14 PM   #17
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Quote:
Originally Posted by 106RALLYE.co.uk
ok just had a look at the calipers and pads. The pads have these little gold clips with them with I presume hold the pads in somehow...

also pads ends are slightly different so need to know which pad goes where, not obvious at the mo with caliper sat on table...

how do the one bolt calipers fit to the strut as there are 2 holes....?
Here are pics of the pads that fit my early-type single-bolt calipers (ignore the brand ). The little clips at the end are like anti-rattle springs and sort of bend round to make the pad sit square in the carrier, if you get what I mean:





The single-bolt calipers refers to the way in which the caliper body is attached to the caliper. On mine, one side is hinged and the other side is a normal bolt. That's why you get at little bolt with threadlock plus a "winged washer" with most makes of pad:





The carrier/caliper is still attached to the strut in the same way, using two bolts:



Finally, you have to use really short caliper screws because all they do is hold the carrier in place; there is no slide action, unlike S1 Rallye brakes:

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Old 26-04-2005, 08:19 PM   #18
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yeah, that's totally different to the 2 bolt ones i've got. you need the larger offset, and the pads are MUCH longer and have square mounts, so i guess the caliper size changed... 2 bolts then give more pad contact on the discs, so i presume give better braking ?

i'll probably get some pics soon when i replace my starter motor. i'll take the wheels off and get some snaps ;]
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Old 27-04-2005, 09:32 PM   #19
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thanks for info....

mmm confusing now, I have got both types of caliper and both types of pad now.

as far as I can see the 2 bolt calipers take the pads with the rounded ends as the pads with square ends are too long to fit in and the ends dont match the caliper.

I've put the pads in the caliper but I cant tell how they are secured in yet?? All I have is the little bag of gold clip thingys...

pads on the 106 have the little bar that holds them in place...
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Old 27-04-2005, 10:16 PM   #20
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i'll get a pic asap, basically the clips go into the carrier, then the pads clip into the clips...

the 2 bolt calipers use the square edged pads, they should be longer than the round ones ?

pics ?
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Old 28-04-2005, 10:46 AM   #21
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Quote:
Originally Posted by Russ W
i'll get a pic asap, basically the clips go into the carrier, then the pads clip into the clips...

the 2 bolt calipers use the square edged pads, they should be longer than the round ones ?

pics ?
yes the square edge pads def longer than the round ones and hence they dont fit my 2 bolt calipers.

ok these little pads clips, any close up pics of how they fit on? are there 2 clips per pad or just one clip per end??
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Old 28-04-2005, 11:00 AM   #22
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one clip per end per pad... the round ended short pads never fit in my carriers, they were about 8mm too short.

my calipers had 2 bolts in them too.
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Old 28-04-2005, 11:05 AM   #23
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some pics...









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Old 28-04-2005, 11:09 AM   #24
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i got the top type calipers and the top type pads... the clips for me are like square C shaped things tho

__/
|
|
--\

sorta like that (how crap is that diagram heh)
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Old 28-04-2005, 06:40 PM   #25
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Quote:
Originally Posted by Russ W
i got the top type calipers and the top type pads... the clips for me are like square C shaped things tho

__/
|
|
--\

sorta like that (how crap is that diagram heh)
russ, there is only one caliper pic above (and its the Bosch 2 bolt one) and the square ended pads DO NOT fit these 2 bolt calipers....are you sure you aint getting mixed up somewhere? what make are your calipers?

If Matt fitted them he will know...
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Old 28-04-2005, 06:42 PM   #26
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they are 2 bolt cos we took them apart.
and the ROUNDED pads DIDN'T fit.

unless i've got the only type of calipers that are different to everyone else in the world.
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Old 28-04-2005, 06:45 PM   #27
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the ones fitted to russ's car are BOSCH calipers..... and the pads are not like either of the 2 you have pictured mark ..........
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Old 28-04-2005, 06:52 PM   #28
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Quote:
Originally Posted by Russ W
unless i've got the only type of calipers that are different to everyone else in the world.
No, I have the two bolt type and they take the square ended pads, the springs that come with the pads insert into the carrier and hold the pad nice and secure.

What pads are they? and why does the material taper off at the edges? wont that just reduce the pad surface area?
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Old 28-04-2005, 07:24 PM   #29
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The Calipers on my old S2 used these shape pads, i removed the clips as it made fiting alot easier.

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Old 28-04-2005, 08:18 PM   #30
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good job I started this topic to colaberate all the information as it appears the caliper/pad combinations are mixed and varied.....

matt/russ - you not get any pics of your pads? Are you sure they are def 206 GTi one's and not similar one's off a Citroen/hdi??

do your calipers look like the one's in my pic???
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Old 28-04-2005, 08:19 PM   #31
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only pic i got for the moment. will take a wheel off and get pics.
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Old 28-04-2005, 08:23 PM   #32
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cheers mate, see if you can get a close up pic of pad clips and pad ends....
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Old 28-04-2005, 08:26 PM   #33
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i gotta do my starter motor this weekend, so i'l just whip a wheel off and see if i can get some snaps.
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Old 29-04-2005, 03:15 PM   #34
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ok more info.....turns out there are 3 types of pad, 1 with square ends, and 2 with round ends but clips differ....

got another set of round ended pads today with different clips and they appear to fit. see pics below, can anyone tell me if the pad clips are in the right positions on the carriers??

Also both Ferodo and OMP supply carrier bolts with their pads but they have a big washer type attachement on them. Question, do I need these type are the normal type bolt that was already in carrier?

and another question, has anyone at all fitted the pad with the clips that come off, loose in pad boxs. see 3rd pic down, right handside pads and clips












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Old 30-04-2005, 01:52 PM   #35
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here you go



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Old 01-05-2005, 08:36 PM   #36
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you have got different calipers and pads to me Russ

anyone else got the rounded end calipers??
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Old 02-05-2005, 04:48 PM   #37
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Mark.

I think I have got the same callipers as you; I will check. If they are what pads fit them and what offset discs, have money burning a hole in my pocket and I need to buy some discs and pads soon.
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Old 03-05-2005, 09:05 PM   #38
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Quote:
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Mark.

I think I have got the same callipers as you; I will check. If they are what pads fit them and what offset discs, have money burning a hole in my pocket and I need to buy some discs and pads soon.
I've fitted standard Ferodo discs and pads for now....mainly because they fitted ok!!

sprayed up calipers 2nite - went for a nice subtle black.

so def no-one else got the same pads and calipers as me so I can check the spring positions??
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Old 11-05-2005, 11:09 AM   #39
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Talking

according to mintex website, there's 2 types of 206 gti pad.




i've got 206 hdi calipers on mine, which use these kind of pads

which are much longer than the gti ones, so there's more braking surface i presume therefore producing more stopping power.

that cleared that up
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Old 11-05-2005, 12:42 PM   #40
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OK then, joining a little bit late into the conversation, so not sure if you really need this pic for reference, but here are my 206 GTI calipers and Pads. These are from a 2000 206 CC.

Any help to anybody for anything??

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Old 14-05-2005, 11:11 PM   #41
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bloody nightmare this 206 brake conversion! so many different variants

ok. so I think we all agree now that there are 3 types of pad for the 206 GTi/HDi.

and I think 3 types of caliper also not 2 as first thought.

anyway...good news got one side finished 2nite. pics coming 2moro when daylight. All went ok, tried one disc but wouldnt fit because of the offset but another OMP disc did the trick. Tired now so cant remember which offset it was that fitted but will check 2moro.

calipers bolted on fine, hose went in ok. will check if any grinding needs to be done when I fit wheel back 2moro.

will do other side 2moro, then bleed system and see how they do with the pedal travel

only thing I cant work out is the carrier bolts that have the big long sided washers on them!!! wouldnt fit to my caliper anyway but may fit others....anyone?
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Old 14-05-2005, 11:13 PM   #42
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the calipers would only need grinding if they didn't bolt straight on... you shouldn't have to do any grinding to clear the wheel.

you probably used the 34mm style discs like me ?
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Old 14-05-2005, 11:32 PM   #43
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Quote:
Originally Posted by Russ W
the calipers would only need grinding if they didn't bolt straight on... you shouldn't have to do any grinding to clear the wheel.

you probably used the 34mm style discs like me ?
nah 34.5mm wouldnt fit, I needed the 27.3mm offset discs. Thats what I mean about all the variations!

it might be so that S1 needs 34.5 and S2 need 27.3mm.

Anyone else with an S2 confirm their offset size???

the 27.3mm 266m discs are the ones fitted to the 306 S16/XSi/405Mi16 and others
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Old 17-05-2005, 12:47 PM   #44
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well 206 brakes are on at last! pics coming soon....

oooh such a tight squeeze under the steelies and the discs nearly as big as the wheels!

still bedding in all my new parts so wont be able to test them for another week or so.

initial feel as expected, lower brake pedal but will stop when right down

need to bleed last bit of air out then we are sorted

one question to clear things up - where are people are grinding the calipers?? If its on the hub mounting then surely you only need to grind if you have the wrong offset discs???
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Old 17-05-2005, 12:49 PM   #45
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It's always confused me too Mark - I have no idea why people are grinding bits off! My calipers almost fell onto the S1 without any fitting issues.

They're nice and tight against the wheel though...
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Old 17-05-2005, 12:57 PM   #46
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Yeah, have to agree with the Great Bamfaggio there. I didnt have to grind anything to fit mine. But 306 GTi brakes on S2 struts might need a bit taken off.
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Old 17-05-2005, 01:05 PM   #47
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yeah, i needed to take a little bit off the actual carrier to make the bolt holes line up.

edit: will see if i can get some pics when i replace my pads tomorrow hopefully.
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Old 17-05-2005, 01:15 PM   #48
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The grinding only applies to the calipers that take the square ended pads.
The offsets are right, part of the carrier has to be ground down so that it can be bolted into the correct position.
If you look here you can see the bit that has to be taken off:

http://public.fotki.com/teamaxe/brakes/

The first picture shows the top of the carrier, after grinding, hard up against the strut. The second picture shows the bottom of the carrier to give you an idea of how much has to come off (as they are symmetrical).
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Old 17-05-2005, 01:27 PM   #49
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yeah that's what had to be taken off mine.
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Old 22-05-2005, 12:18 PM   #50
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some fitted pics at last.....







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