Been nearly a year since I sourced the parts, time flies when you're having fun.
Haven't even driven it since last October or so.
Here we have the disk brake swap. On the left is the drum assembly, then rotor, softline, caliper adapter, brakeline clips and caliper bolt locks, hardline, caliper, caliper bolts, and dust shield. The drum brake assembly weighed in at 20#, the disk parts at 29#. 9# more unsprung weight sucks, but a small price to pay.
Started by removing the drum, bearings, softline, and backing plate/brake assembly.
The I mounted the caliper adapter and dust shield. Forgot to take pics... but this was the most involved part of the swap.
The caliper adapters are not identical, but either one can be used on either side. I spent a couple hours test fitting things to find the one that best located the pads on the rotor. There's a fine line here - too far outboard, the pads hang over the edge of the rotor; too far in and the dust seal rubs on the hub.
I (think I) wound up swapping side-to-side. This was mostly done to rotate the brake assembly enough that the brake line retainer on the backing plate so that it would clear the steering uprights. But too much rotation and there's not enough meat on the caliper adapter for the bolt.
Anyway, once I figured out which and where I wanted to install, I marked the holes, plug welded an existing hole that was adjacent to a new hole, and drilled away.
Once that was done, a simple matter of installing the rotor, bearings, and dust cap. Gave it a spin by hand to be sure there was no interference with anything.
Installed the caliper, and started bending the line. Hadn't done this before, but pretty easy. Only trick was cutting/flaring the new line - old Volvos are weird, in that they use a metric-style bubble flare on the caliper end (with 3/8x24 SAE thread) and SAE-style inverted (double) flare on the rest of it. Borrowed a flaring tool from the FLAPS, and after a few tries, got it pretty good... wound up having to do one over again due to a fluid leak, but not too big a deal.
Wrapped the line up and around the caliper, keeping it tight to the caliper to stay clear of the wheel.
Then hooked up the new softline.
My older son is getting to be a pro at bleeding brakes, even remarked when he started to feel solidity. And he doesn't grumble about the job like SWMBO does.
Easiest bleed ever, used my transmission funnel to get the brake fluid in. Why Volvo put the master on the frame rail is beyond me.
Put the tires back on, took it for a road test.
these are about the best feeling brakes I've ever driven. I bet a lot is the lack of power assist, but they are rock solid, easily modulated, and really stop the car nicely. Found a steep hill, and repeatedly laid into the brakes in an effort to elicit fade or misbehavior of any sort. Nope.
Hardest part of this job (other than pulling the old brakes at the JY surrounded by wasps) was figuring out how to position the caliper adapters. After that, gravy.
So, now that I have safety (seatbelts), cornering (tires), and stopping, it's time to investigate more power.
Like a lot more.
//edit - oh yeah, haven't addressed the shocks yet (they hit the calipers and limit steering). While it's still livable, the turning radius is on par with (or worse than) our 04 v70, a legendary bus-like turner if ever one existed.