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Thread: RX7 adapter for bigger rotor's (276mm) 15 Rim

  1. #1
    Senior Member dave2221's Avatar
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    Default RX7 adapter for bigger rotor's (276mm) 15" Rim


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    This is only an expression of interest. and for a 1 off run only.

    other than that i can get out in touch with who i use and they will charge you whatever they want.

    AJPS sells RX7 caliper adapters, and i dont want to chop into his business.

    but i would like to go to a 276mm rotor from a 2000-2001 mini cooper

    So that means that i have to make a custom adapter, from the plans available on the net........ as such since ill be getting it done by a proper CNC machine, the more i get done, the cheaper it becomes.

    The Mini rotor is a 276mm diameter, 22mm thick, 64mm center hole. while the EG civic is: 262mm diameter, 20mm thick and 64mm center hole.

    DBA part number for the mini rotor is: Street:542SL (left) and 542SR (right). The S is for slotted, and the L/R is for side.
    Also available in 4000 series: 4542SL and 4542SR

    everything else for the upgrade is the same, just a different adapter and a different rotor.

    So would anyone be interested in a RX7 caliper adapter to take a bigger rotor.

    ADVANTAGES:
    Bigger, more heat distribution = less brake fade

    DISADVANTAGES:
    prob wont be able to run anything less than a 15" rim.

    so yeah let me know and ill try to organise it.

    if not i might just do it myself, or if it gets to hard AJPS here i come.

    Quote Originally Posted by Oly AE86 View Post
    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 ****





    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, 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.






    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 boosted 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.






    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.



  • #2
    Senior Member 4.5AG's Avatar
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    count me in

  • #3
    Senior Member rallystanza's Avatar
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    Will these be made of steel and therefore engineerable, if made with correct material?

    Very interestedn pending a few things.

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    Senior Member dave2221's Avatar
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    yes, they will be fully engineerable. i will be doing this the long way, using the appropriate materials and a proper CNC machining factory.

    i am arranging for a quote to see if its cost effective

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    it sucks i cant open the files on my computer to see the drawings

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    Senior Member Oly AE86's Avatar
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