FC Front Brake Upgrade

[Oly AE86]

AE86 Brake Upgrade Using RX7 FC3S Calipers and Mini Cooper S Rotors.

Items required:

*Brake Calipers, 1990 Approx RX7 Series 4/5 Turbo $135 Calipers, $160 to rebuild
*Brake Pads, Brakes Plus Premium Plus $75 Trade
*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. I have dimensioned CAD drawings if anyone is interested.
Link to CAD Drawings of Bracket



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.



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, so 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.

Then, assemble the whole setup. Original AE86 brake lines can be used, or replacement braided units (ex. From AJPS $180) would sweeten up the system. Original master cylinder can also be used, with a T-18 rear end my pedal feels squishy at first, then firms up. Nissan R32 non-ABS units apparently bolt straight on, with 15/16 bore create better pedal feel, will try that next.

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 am currently running a 7mm spacer, and looking into either different offset 15'' or another SSR wheel.

There is no problem with clearing the LCA, other setups use a rotor with high offset that requires NCRCA's, I do have these fitted but are not necessary.

[70XIN]

awesome article. will be a great lot of help in the near future

did you just take the dimensions down to a machining shop? or have you made up a CAD drawing yourself?

[Oly AE86]

I got some CAD drawings from Twinky on Toymods, changed them around so they are easier to understand and took them to work.

The guys drew them on the CNC and the machine did the rest. I think if you took the printed drawings to a machine shop they could make them without too much hassle.

[Tom86]

What the stopping power like now? is it worth the effort?

[Oly AE86]

Its pretty good once the rotors get a bit of warmth into them. When they are cold or if I start driving when its raining they take a bit to warm up and work well.

I am putting in the R32 master this weekend, should take away the spongy feel and improve the bite.

[Bustin_86]

thats awesome man... many thanks for such a comprehensive article!

[RobertoX]

good work man! thx for the plug

[Hen is a total nutcase]

Wow, those adaptors are awesome. Whoever designed them must have been a genius.

Hen

[Oly AE86]

Yea, thanks Hen! Without your originals these would not have been created.

[70XIN]

Thanks for your reply!

Oh, and another quick question .. who would be a good person to try for the lathe work on the brakes?

And in regards to the adaptors, would your work be able to make up a couple more? I have the brake calipers and the money waiting, i was just a bit scared to do the upgrade until now