Toymods Car Club Inc: Tech & Conversions => "bolt on" brake conversion options for FWD/4WD 5 x 100 stud pattern

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wagonist
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May 2002

Re: brake conversion options for 5 x 100 stud pattern	Mon, 11 October 2004 06:17

The four piston calliper, due to its size is mounted on the other side of the hub. This means that the calliper is drilled while the ST205 hub is tapped. (The wheel nuts are temporary for mounting purposes) *The calipers need to be modified to make the disc central. See later posts for further details* All 3 callipers have the same spacing for the mounting holes. The extra wire with green clip is for the ABS The bolts for the ST205 are the same overall diameter as the others ST205 & ST185 This means the hubs need to be drilled out & tapped to accept a bigger bolt that will go through the ST205 calliper. The calliper also needs to be drilled out to accept the larger bolts. Any machine shop should be able to do this accurately. ST205 M12 bolt & replacement M14 bolt (yet to be shortened) These are all high tensile parts The next big hurdle was when I tried to fit the disc & calliper onto the hub at the same time. While the disc went on, & the calliper offset is correct, the mounting holes for the calliper didnt line up by about 5mm. Because the ST205 Celica GT4 has a unique double wishbone suspension, it was created around these brakes. Therefore the mounting holes have been positioned further out. The fix for this is to get the disc machined down from 315mm diameter to 300mm diameter. I had been told that this was required, but the reason was so that the ST185 wheels cleared the callipers, but now we know the truth. ST205 disc after being machined down to 300mm The last hurdle is to get new front brake lines. Because the ST205 calliper is so large, the original flexible brake lines do not reach. The ST205 has a solid metal line running from the calliper to the upper wishbone, then a flexible line from there. Disc & Calliper fitted to car (yes theyd been painted by now) I was able to overcome this problem by using brake lines off of the current ZZE122R Corolla. They were the same length from the car to the strut, but about 2cm longer from the strut to the calliper. To improve the length again, I bent the bracket that holds the brake line to the strut forward slightly. My car is a 96 model where the brake line bolts to the strut, earlier cars with clips may have to source other lines (or do custom braided ones) Caldina hose at the top vs Corolla hose Due to the width of the callipers, there is now a very tight fit between them & the wheel. Tight clearance of about 5mm Because of the offset clearance, most 17 rims will not clear these, although the ones pictured will. (If youre game to drive with 18 rims, you may have better luck) Thanks for this go to Gary (GEE120) for letting me measure up his ST205, & Andrew (RAV-GT4) for not wanting to use the brakes on his conversion & selling them to me. BTW before you have any machining done on the disc, make sure they have thickness left in them. In had mine "faced" before I reduced the diameter. They are now on min thickness, so I would've much rather spent the money on getting new discs first. [Updated on: Wed, 10 November 2004 00:53] [Report message to a moderator]

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