Document 6511493

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Document 6511493

Toymods Car Club Inc: Tech & Conversions => How to fit RX7 calipers to an AE86 - Links to pics
12/20/2005 10:24 PM
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Henn
Forums Junkie
How to fit RX7 calipers to an AE86 - Links to
Mon, 09 May 2005 20:47
pics
Recently I have been getting regular emails about the RX7 brake setup I have on
my Sprinter and so I thought I might write this up once rather than responding
individually.
The aim was to keep stock struts (whether this is a good idea can be debated)
and this is the setup I eventually got to work.
Location:
Rosanna, Melb
Registered:
June 2002
Photos thanks to imageshack.us Brakes from front
Brakes from rear showing stepped adaptor
Brakes from rear showing more of the adaptor
[add to buddy list]
[ignore all posts by this user] It consists of:
Stock strut
Stock hub
Stock lower control arm and steering arm
CalipersS4 RX7. Some of the fins on the caliper had to be filed to fit them under 15"
rims. Plus the lump near where it says MAZDA had to be filed down to clear the
wheel spokes... however DONT FILE IT FULLY FLAT otherwise you open a brake
line. Leave at least 2-3mm proud.
Disc280mm 180SX (from SR20 variety I think). Needs to be redrilled to suit stud
pattern on the BACK of the sprinter hub.
LocatorCustom locator ring so disc fits snugly on AE86 hub.
Locator pic
Locator drawing
Brake mounting plateCustom. This was the part which took ages to make but it worked in the end. I
made them from 450MPa steel although I think you could probably make it from
good alloy and it would be strong enough. I've been quoted around $6-700 a
pair to machine these adaptors.
Pics of adaptor only: 1 2 3
Drawings of adaptor: 1 2 3 4
Models showing fillets on the corners: Front Back
And an old page I just dug up where Garth hosted most of these pics a couple of
years ago. Thanks for keeping it up.
Problems-
http://forums.toymods.org.au/index.php?t=msg&th=68402&start=0&rid=2739&S=fce8b2a8623cad89d1bd1d5b9cf2668f%3Cbr%20/%3E
Page 1 of 8
12/20/2005 10:24 PM
The main problem I ran into was that if the caliper sat inboard of the spokes of
my wheels then the disc rubbed on the lower control arm. My Superlights only
have 6-7mm of space between the wheel mounting face and the inside of the
spokes. I got around this by running offset roll centre adjusters which pushed the
bottom of the strut (and therefore hub and disc) out 17mm.
Offset RCA
If you plan on doing this upgrade and have more room outboard of your wheel
mounting face then you could redesign the adaptor to mount the caliper further
outboard. This removes the need for offset RCAs and also makes the adaptor
both stronger and easier to machine. This would require a new disc be chosen
with the correct offset. I seem to remeber Audi A3 discs were an option.
ResultsI've used these for almost 18months and they are great. With EBC greenstuffs I
have never had them fade even when trying on track (with 110rwkw).
In conclusion I wouldn't recommend doing this, it is total overkill and I think
there are cheaper and easier upgrades out there. However some of you I'm sure
will not be put off (like me) and want the bling of 4piston brakes. If so then good
luck and please consider the time and effort I poured into this setup and help me
out with a favour some day.
Hen
Sooking on the internet will help solve your problems.
[ Report message to a moderator]
ShiRi
Forums Junkie
Re: How to fit RX7 calipers to an AE86 - Links to
pics
excellent comprhensive guide to it henn
Mon, 09 May 2005 20:56
hats off
#trd-spec on Austnet mIRC
Victoria's Toyota Club
Location:
Melbourne
Registered:
June 2004
[add to buddy list]
[ignore all posts by this user]
Big T
Forums Junkie
pics
Mon, 09 May 2005 21:26
And I'm one of the people that keep pestering you Henn
Been doing a bit of
research to see what disk would be best for the plate as well.
The A3 disks are the closest you'll get to machining the plate dead flat. There still
has to be a 3.7mm step on the plate.
Location:
Sydney
Registered:
September 2004
[add to buddy list]
I've looked through almost ALL of the DBA catalogue to try and get an exact
match but no luck, (i think there were a couple other matches as well but only
had a 260(?)mm rotor)
The rotor height would have to be 33mm in order to machine it flat.
Page 2 of 8
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12/20/2005 10:24 PM
I'm actually trying to find pre-made adaptor plates from Japan for the rx7
calipers. Garth linked me to a site that had Honda disks on a custom adaptor.
Trying to find one for the fc brakes.
Eddie.
Cars
1. AE86 Sprinter Trueno Coupe. (4agTe is coming.)
2. AE71 Corolla Sedan. (currently undergoing Bigport 4age transplant.) SOLD!!! To an
Irishman yelling HI 5!!!
3. KE70 Corolla Sedan. (taken away by the council... was fun wrecking it though!)
4. Subaru Impreza RS. (daily driver.)
YelloRolla
Forums Junkie
pics
That is excellent Henn.
Mon, 09 May 2005 22:11
The 24.8deg measurement (drwg of adaptor #4) had me stumped for a bit - I
take it to be the angle that the back flat edge of the bracket sits when installed.
Location:
On your mum!
Registered:
May 2002
[add to buddy list]
Jason
I need to consult my diary before attempting overtaking moves with my KE70.
73 KE20 Corolla + 3T GTE with Wolf ver 3.0
60' - 1.56
1/8 mi - 7.50 @ 93mph
1/4 mi - 11.82 @ 115mph
Jimmy19650
Occasional Poster
Location:
Wodonga
Registered:
pics
Great info Hen,
My only question with this setup is whether you need to modify the brake master
cylinder at all? Have you got any ideas on rear brakes as well?
May 2005
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pepsicola
Forums Junkie
Location:
Melbourne
Registered:
Mon, 09 May 2005 22:26
pics
thanks for the info, that's really good description.
Mon, 09 May 2005 22:35
-Big Ttry z31 300zx rotors, they're 33.5 height and about 280mm diameter.
August 2002
[add to buddy list]
only problem is that i've got one of these from a brand other than DBA, the rotor
[ignore all posts by this user] can't be redrill to fit behind the sprinter hub.
[Updated on: Mon, 09 May 2005 22:37]
Page 3 of 8
pepsicola
Forums Junkie
12/20/2005 10:24 PM
pics
oh, and what brake hose do u use?
Mon, 09 May 2005 22:46
Location:
Melbourne
Registered:
August 2002
[add to buddy list]
Big T
Forums Junkie
pics
Mon, 09 May 2005 22:59
pepsicola wrote on Mon, 09 May 2005 22:35
thanks for the info, that's really good description.
-Big Ttry z31 300zx rotors, they're 33.5 height and about 280mm diameter.
Location:
Sydney
Registered:
only problem is that i've got one of these from a brand other than DBA, the
rotor can't be redrill to fit behind the sprinter hub.
September 2004
[add to buddy list]
The z31 rotors are 35.5mm and the centre hole is massive (81mm) in
comparison to the sprinter's one. I'm no engineer so i don't know if using a rotor
with a centre size difference that large would be advisable.
I was looking at the closest possible match in all the categories. The A3 disk is
280mm wide, 36.7 high, 22mm thick and the centre hole is only 1mm larger
than the sprinter at 65mm.
Eddie.
Cars
Mon, 09 May 2005 23:02
pics
although the stud pattern is different can you use a honda NSX 91-98 model.
the rear disc has the following dimensions:
Location:
model 485
Adelaide
vented
Registered:
September 2003
282mm diameter
[add to buddy list]
hat height 32.5mm
[ignore all posts by this user] rotor height 21mm
centre hole 69 mm
5 stud pattern (this could be the killer)
barned01
Regular
would that make it pretty close?
Page 4 of 8
12/20/2005 10:24 PM
Big T
Forums Junkie
Mon, 09 May 2005 23:14
pics
I was actually trying to source out the disks 2nd hand so i automatically
dismissed that one. I mean how often do you see an NSX being scrapped!!!
Obviously the audi disks won't be easy to find either which is why i'm not
committing to any plans yet. If i find a suitable adaptor plate from Japan, i'll post
up the link.
Location:
Sydney
Registered:
And i don't think the actual stud pattern matters on the rotor. The A3 disks are
also 5 stud but they can easily be re-drilled to suit the sprinter hub.
September 2004
Eddie.
[add to buddy list]
Cars
barned01
Regular
Location:
Adelaide
Registered:
pics
is there a reason why you wouldn't buy them new?
expense?
Mon, 09 May 2005 23:17
September 2003
[add to buddy list]
oldcorollas
Forums Junkie
Mon, 09 May 2005 23:35
pics
yes. they are also an "option" for oldcorolla brakes, but at around $300+ per disc
from DBA, they are a little.... pricey...
"I'm a Doctor, not a mechanic"
Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Big T
Forums Junkie
pics
Mon, 09 May 2005 23:36
Page 5 of 8
12/20/2005 10:24 PM
pics
barned01 wrote on Mon, 09 May 2005 23:17
is there a reason why you wouldn't buy them new?
expense?
Location:
Sydney
Registered:
September 2004
That's my reason at the moment. My turbo conversion has just passed into the
8k bracket so if i can get comparable stuff 2nd hand, i'll look at that 1st.
I mean stuff like head gaskets, piston rings, bearings etc you have to get new
but brakes are doable well with 2nd hand bits.
[add to buddy list]
All them little bits and pieces keep adding up.
If i can't find decent 2nd hand
gear then i'll have to go for new but i'd like to exhaust the other options 1st.
Eddie.
p.s. sorry for the semi-hijack of the thread Henn!!
Cars
pepsicola
Forums Junkie
Location:
Melbourne
Registered:
August 2002
[add to buddy list]
Tue, 10 May 2005 00:38
pics
um...have u thought about putting the rotor over the hub instead of put it behind
the hub?
i think i've seen it done this way, by machining the hub diameter to a bit smaller,
redrill the rotor (stock rx-7 maybe) to 4x114.3 stud pattern. put it over the hub
and use longer studs.
this way, u should be able to use rotors that has around 60-70mm.
and u could probly get more clearance between the caliper and the wheel spokes.
Jonny2TG
Forums Junkie
Location:
Tasmania
Registered:
May 2002
[add to buddy list]
Henn
Forums Junkie
Tue, 10 May 2005 00:57
pics
The RX7 brakes are a common converion in Japan, with adapter plates sold on
YahooAuctions at times. Some of us need to spend more time on the Japan
websites to see what disks they use with the adapters they have. Whats the
biggest diameter disk you can use in a 15" wheel?
Jonny Rochester
TE37 Levin - 2T-G
AE86 Levin - 4A-GE 20
Tue, 10 May 2005 09:41
pics
Pepsi - I never thought of sliding the disc over the hub when I did this, however
Page 6 of 8
12/20/2005 10:24 PM
thinking about it since it seems like it could be a good idea. I think Mrshin has
done something similar.
Yellowrolla - the 24.8 degrees is just so the caliper sits in about the same
orientation as the factory caliper. The centreline of the two mounting holes is
24.8 deg below horizontal when the bottom strut mounting bolt is vertically
below the centre of the hole the stub axle sticks through (a result of the way I
drew the pictures up)
Location:
Rosanna, Melb
Registered:
June 2002
Jimmy - I run a 15/16th master off a Corona which I had to redrill. However
[add to buddy list]
there are bolt up 15/16th and maybe even 1" masters available. Starion and
MA70 Supra spring to mind but I am not sure on either. The stock master will
apparently work, according to Mrshin again, but just give you a really soggy
pedal feel.
I've heard similar things are avavilable off the shelf from Japan and may end up
being cheaper and definitely easier, but the info is also here in case it's any use.
Hen
Sooking on the internet will help solve your problems.
pics
Thanks for that Henn, ive added it to the sticky.
takai
Forums Junkie
Tue, 10 May 2005 10:20
As for master cylinders there are a few out there you can use which bolt up.
Mitsu Starion is a 15/16th master, and is currently paired up nicely with my Hilux
4spots.
Nissan R32 GTR is either a 1" or 1 1/16th master depending on which version
you get (BM50 or BM57) Ill probably use this when i try and fit GTSt calipers
under 14" rims.
Location:
Adelaide
Registered:
May 2003
--takai
I cant get no sleep...
AE92 4A-GZE MAP, 109.23FWkW
Project Sparky - AE86
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Document 6511493

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