Front Brake Upgrade: RX7 4 Piston caliper and 276mm Rotor

[Oly AE86]

AE86 Brake Upgrade Using RX7 FC3S Calipers.

Items required:

Brake Calipers, 1990 Approx RX7 Series 4/5 Turbo $135 Calipers, $160 to rebuild
2001 Mini Cooper S Rotors, 276mm dia, 22mm thick, 64mm centre hole (same as AE86) DBA P.N. 542 RDA P.N. 7352S (slotted) $285 Pair
Custom made bracket to fit Calipers to AE86 Hubs
4x M12 x 30mm Cap Head Bolts
8x M12 x 35mm Cap Head Bolts


First, brake adapter bracket.

Using CAD drawings from Twinky on Toymods , brackets are milled from solid steel on CNC. These were made cheaply by some guys at work, but with the drawings I think any fabrication shop could do it. Cad drawings are available **** Here **** (http://www.mediafire.com/?nycda9b080nw8)

Free Viewer/Printer for DWG and DWF > Here (http://usa.autodesk.com/design-review/download/?id=12423405&siteID=123112)

http://www.ae86drivingclub.com.au/dcimages/1/4/2/10000.jpg http://img9.imageshack.us/img9/1299/fillet10wtk.jpg http://img9.imageshack.us/img9/1369/tocncc.jpg



Second, modify Mini rotors



The rotors have a chamfer on the inside where they locate on the hub, a new chamfer needs to be made on the opposite side to fit over the AE86 hub, this can be done on a lathe in a few minutes.

http://img291.imageshack.us/img291/5056/img1489y.jpg



Third, modify Sprinter hub



Because the disk is so much larger, I replaced the standard M10 bolts that mount the disc on the hub with new High Tensile M12 items, to the holes on the hub were drilled out to 10.2mm, and re-tapped at M12. Then, using the AE86 hub, re-drill holes in rotors to mount onto reverse of hub, PCD is about 87mm but having the old rotors and hubs you have a template.


http://img519.imageshack.us/img519/8113/img1490.jpg



Then, assemble the whole setup. Original AE86 brake lines can be used, or replacement braided units (ex. From AJPS $180) sweeten up the system. Original master cylinder can also be used, with a T-18 rear end my pedal felt a bit squishy at first, then firms up. Nissan Skyline R32 non-ABS is now installed and pedal feel is much firmer and stronger. Master bolts onto original booster and I bent original hard lines to suit. Had to shorten one hard line and re-flare but it wasn't difficult. Passed QLD Mod plate test with ease, stopping from 60km/h in 19m with Bridgestone RE001 195/50 Tyres.


http://img17.imageshack.us/img17/5828/brakep.jpg http://img21.imageshack.us/img21/9931/topbrake.jpg



Clearance is good with 15’’ SSR wheels, about 1cm to the outside of the rim. There is a clearance issue with the spokes so I ran a 7mm spacer. Currently running Watanabe RS 15 x 8.5 -6 and running an 11mm custom spacer. Wheels without dish or wheels designed for more modern cars (Rota Grid 16x8 +10 for Example) fit without any spacers.


http://img257.imageshack.us/img257/46/completeunitsml.jpg

[NIZLAH]

Awesome write up Oly.... the easiest and clearest guide I've come across so far..

[dr1ft-pig]

good article man, props

[Oversized 86]

good write up...however i think your prices are alittle wrong...

the calipers are definately more than $160 to rebuild...

[AE71briskev]

hey there does ne one have a set of these not on there car yet in brisbane my uncle owns his own cnc machine company and i can get them made up for next to nothing for me hehe

[Oly AE86]

good write up...however i think your prices are alittle wrong...

the calipers are definately more than $160 to rebuild...

When I had my Calipers rebuilt, its was $80 per. That included new seals, rebuild labor and cleaning/painting, pistons were prefect.

[Oversized 86]

thats bullshit cheap hey...
how long ago did you have that done?

[Javal]

thats bullshit cheap hey...
how long ago did you have that done?

Generally speaking, the pistons are the expensive part of having your calipers rebuilt. If they're fine, It's a cheap exercise like it was for Oly. If they all need replacing, the bill gets quite large.

[Oversized 86]

mmm...thats probably why the rebuild of mine cost well over $300

[Chrisso]

Hey Oly. Cheers for the write up again. I was looking for it but obviously deleted when the old boards went. If you want them for reference Hen sent me an updated version of files based on your drawings/design. I haven't looked at them yet, been otherwise occupied, so I don't know what was changed.

Chris.

PS. Cost me $80 for two rebuild kits from PBR, took a couple of hours to clean (most of the time), paint and rebuild.

[RacerMelb]

Oly, you are a super star, thanks for the detail in the post, just finished doing the conversion on mine and was going to replace the whole booster to the S13 one then change the master as well, but after reading the thread you saved me having to hunt down a booster. Cheers for your input, this is the spirit of comunity, and the real reason behind these types of forums, I take my hat off to you.

Jon

[Nic19]

guessing 14's have no chance then lol

[ke_70]

^ my AJPS kit does fit most 14 inch wheels

ssr reverse mesh 14"??

[nelpd96|]

That is a cut and paste from the FAQ, other brake upgrades are listed as well.
http://www.ae86drivingclub.com.au/faq/index.php/Brake#Corona.2FMX62.2FRA60

To be honest I though that all the work was done by Henn back in 2005 and it was listed on the old Toymods forum.

http://forums.toymods.org.au/index.php?t=msg&th=68402&rid=&S=2a71a913fa7752ec290dcd9aed7da26c&pl_view=&start=0#msg_636691

So unless Oly AE86 = Henn then I would be carefull taking credit for someone elses work....

[Chrisso]

Perhaps a note should be here somewhere.

However, Hen and Oly are aware of each other's designs and Oly has previously credited Hen with the inital set up. Oly's design is an improvement on Hen's work and fixes some of the compromises that were inherent in Hen's original design.

Hen's write up is interesting background, but the best end result is to use Oly's set up. I sent Hen a copy of the drawings at the beginning of this year.

Chris

[Oly AE86]

Using CAD drawings from Twinky on Toymods

I got the CAD files from Twinky on Toymods, who originally got them from Henn yes.

I don't say anywhere that I created the design for the brackets, or take any credit for them. :right: ??

This is simply a guide on what to use in the conversion.

[Hen may possibly be a nut]

Yeah, I drew up the original drawings with some graph paper and a set of calipers some time in 2003. And it's been passed around a bit since then.

My original drawings were a mess (and using the S13 discs to clear my wheels wasn't the best choice) and Oly (or Twinky) cleaned them up a lot. From that I've gone back and made a much nicer solidworks model of them too, so if anyone wants, they are welcome to that (or .dxf or whatever format you prefer).

I don't think anyone's done anything wrong. The only thing that'd piss me off is if someone tried ot make a profit based on the drawings.

Hen

[nelpd96|]

Sorry, if I have cause offence by what I have said. I wasn't trying to point fingers meary highlight that there has been work done on this before. I would just hate to see people taking credit for someone elses work, which obviously isn't the case here.

Again sorry if I have offended anyone by my comments.

Regards
Paul

[Nic19]

hey hen, wat wud a place charge to make these from the drawings? wats the solidworks model they the ones to run the mini rotors? also would these clear 15x8 -9 challenegers?

[Hen may possibly be a nut]

Nic, last time I asked (2004) I got a price of $600 a pair machined from a single chunk of 450MPa steel. You could get it much cheaper if you had friends with a CNC mill, or used aluminium instead (should hold, but discuss with an engineer etc, etc).

I have a model for both Mini rotors and S13 rotors. Only difference is offset and disc diameter.

NFI on the challenger clearance. S13 setup cleared my Superlights, which had 6-7mm clearance behind the spokes, outboard of the mounting face. Mini setup sits 5?? mm further outboard.

Hen

[Nic19]

hmmmm might go with the ajps ones as i have 14's at the moment and dont wanna limit my options too much, would be sweet brakes tho

[cswan]

There's also a free CAD drawing editor called DraftSight which you can use.

2D only but cool.

http://www.3ds.com/products-services/draftsight/download-draftsight/#xtor=AD-508-[swfreetools]-[middle]-[intext]-[www.solidworks.com]

[troublesome_7]

You can make series 4/5 calipers fit under a 14" rim. You will have to grind off bits of the caliper in various sections but you can get it to work.