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Location:
Melb, Victoria
Registered:
September 2002
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Superstrut disc straight fit (almost)
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Mon, 16 June 2003 06:52
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I finally fitted the superstrut brakes to my AE92 over the weekend. After hours of researching the DBA catalogue i've found a disc with the right offset, diameter and stud pattern. The only thing that will stop it from fitting straight on is the corolla flange being about 1 or 2mm too big in diameter, this is easily machined to accept and locate the disc. The discs are from a 1998 model Mazda Astina, DBA part number - DBA258, these discs are made by Brembo.
The only mod required is the machining of the outer edge.
Offset is perfect
DBA258 compared to standard AE92
Finished product.
Vic.
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Location:
Coffs
Registered:
May 2002
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Re: Superstrut disc straight fit (almost)
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Mon, 16 June 2003 07:00
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Looks hell nice. Have to tested them on the road yet??
What model AE92 do you have?? What did the disc's cost you??
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Location:
Melb, Victoria
Registered:
September 2002
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Re: Superstrut disc straight fit (almost)
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Mon, 16 June 2003 07:10
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On the road there is no way to describe the stopping power compared to the standard brakes. I've got a AE92 sedan with a GZE, i posted up some pics a few months ago in General if you do a seach on my user name you should be able to find them if you're interested. The disc cost me $100 each (trade).
Vic.
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Location:
QLD - Sunshine Coast
Registered:
July 2002
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Re: Superstrut disc straight fit (almost)
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Mon, 16 June 2003 08:22
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Firstly the DBA part number is wrong. The only Mazda Astina disc that is 24mm thick (according to the Mazda PDF files I downloaded from the DBA site) is the DBA537.
Secondly it is NOT the outer part of the disc you have identified with your arrow that centres and locates the disc, rather it is the centre hole of the disc. The AE92 Corolla uses a 54mm centre hole and the Mazda disc uses a 55mm centre hole - a combination inviting a wheel balance problem IF your method of location doesn't work.
Thirdly it's a real pity you wasted so much time sifting through the DBA parts listing because if you had looked around the twincam16 site you also posted this on you'd have found that this swap has been done (several times), and documented (recently - see link below), using (with all due respect) a better selection of parts to suit the conversion, so all of this work has already been done for you  .
http://pub131.ezboard.com/ffwdtoyotafrm2.showMessa ge?topicID=3369.topic
Later
Shane
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Location:
Melb, Victoria
Registered:
September 2002
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Re: Superstrut disc straight fit (almost)
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Mon, 16 June 2003 23:08
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Firstly my apologies, the DBA part number is DBA537.
Secondly the outer part of the flange that i have arrowed is the part that requires machining to fit the disc, seeing that the center hole of the disc is 55mm and the corolla hub is 54mm i've used the flange to center the disc as long as it has been macined properly so there is no need to machine the center hole of the disc and make a locater.
Thirdly it's a real pity that you can't accept that someone has tried a different method to your own and has been successful. I've read your post and others on the subject and then decided there must be an easier way to do the conversion rather than drilling and machining the disc to suit. I've also spoken to brake specialist and an engineer who didn't like the idea turning a 5 stud disc into swiss cheese with 9 holes weakning the surface. So i've satisfied my engineer and i can use a disc that is easily replaced at $100 per side and no need for machining
Vic.
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Superstrut disc straight fit (almost)
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Mon, 16 June 2003 23:25
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I reckon that brake setup looks hella cool 
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Location:
Coffs
Registered:
May 2002
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Re: Superstrut disc straight fit (almost)
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Mon, 16 June 2003 23:39
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Hella yeah looks hell sexy.
I'm with the idea of not having any more then needed stud holes in the disc.
And if the engneering is kool with what you have done it must be a damn good job.
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I supported Toymods
Location:
I renounced punctuation
Registered:
May 2002
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Re: Superstrut disc straight fit (almost)
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Mon, 16 June 2003 23:40
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Good effort. Certainly fits well but some minor criticisms.
| RSSTi wrote on Tue, 17 June 2003 09:08 |
I've also spoken to brake specialist and an engineer who didn't like the idea turning a 5 stud disc into swiss cheese with 9 holes weakning the surface.
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You can order blank undrilled discs from DBA if you are prepared to wait (particularly with low volume, low turnover items).
I am surprised your engineer allowed the rotor to be located using the hat (it's the weakest part of the rotor). When faced with a similar problem, an engineer I spoke to suggested machining the central spigot hole and making a locator collet. I suppose you have someone to sue should the hat break!
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Location:
Darwin
Registered:
April 2003
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Re: Superstrut disc straight fit (almost)
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Tue, 17 June 2003 02:10
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Great effort RSSTi. Looks awesome!
And for that price I reckon that's fantastic.
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Location:
Sydney
Registered:
May 2002
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Re: Superstrut disc straight fit (almost)
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Tue, 17 June 2003 04:31
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ok, a few things here..
Shano2,
Relax buddy, u came in here with what seemed like an attitude.
Hes trying something different to your method and if it works good on him..
Why dont you just castrate the guy for not visiting your hangout  i frankly dont care which method he chose to use.. if he did it himself and it works.. claps all round. 
Ive done this conversion as well.. Not on a corolla.. but the same struts as an ae82.
now..
A few things.. as for your grinding the caliper down a bit? WTF?
I didnt do this.. i just ground the original disc down by like 3-4mm and it fits perfect.. never had a prob.. and they pull up really really well.
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Location:
Brisbane
Registered:
May 2002
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Re: Superstrut disc straight fit (almost)
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Wed, 18 June 2003 01:11
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part of the caliper clashes with a section of the ae92 hub when you try to bolt it on, so you have to grind a tad off it so it is shaped the same as the ae92 caliper
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Location:
QLD - Sunshine Coast
Registered:
July 2002
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Re: Superstrut disc straight fit (almost)
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Wed, 18 June 2003 01:27
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Corvid,
I am quite relaxed but thanks for your concern 
If you had checked this post at the TC16 forums, and my subsequent reply you would have seen there was no intent to make personal attacks against RSSTi or display any "attitude" (I love my attitude problem ), far from it (unlike his reply - but hey that's cool I'm a big boy I can live with that) and also that I NEVER at any point said this wouldn't work (although I agree with Gianttomato) I just noted that he had some mior details wrong and he had spent heaps of time researching something that had already been done for him and many different options provided.
But as I said at TC16 good for him if he made it work, there's lots of different ways to skin a cat.
As for the grinding of the calipers - Are you refering to Superstrut calipers or just normal AE101 single piston calipers?
I have done this swap (Superstrut calipers onto AE92) about 7-8 times now and each and every time the caliper has needed to be relieved to fit without hitting the centre of the hub - the AE101 and AE111 single piston calipers however will bolt straight on.
Finally the ONLY reason I bothered to post this here at all is that I was told the same post existed at both sites and it was suggested (by a Toymods board member) that I re-post the exact same reply here.
Cheers
Shane
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Location:
Melb, Victoria
Registered:
September 2002
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Re: Superstrut disc straight fit (almost)
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Wed, 18 June 2003 05:29
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| gianttomato wrote on Tue, 17 June 2003 09:40 |
I am surprised your engineer allowed the rotor to be located using the hat (it's the weakest part of the rotor)
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I've been told that this will locate (center) the disc, once the wheel is bolted on it will clamp the disc into place so there shouldn't be any load on that part of the rotor.
Other than that i'll keep my ideas to my self from now on.
Vic.
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Location:
Brisbane
Registered:
May 2002
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Re: Superstrut disc straight fit (almost)
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Wed, 18 June 2003 05:35
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I think it's good to share idea's...
I've had quite a lot of people laugh at the many uses of rope I've concocted during my engine conversions
How did you machine down the hub?
is the disc an interferance fit over the hub? or is there some room?
Jason
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: Superstrut disc straight fit (almost)
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Wed, 18 June 2003 08:21
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sharing idea's is good.
That way people can work on them, improve them, point out possible flaws etc so that eventually it can be perfected and beneficial to all toyota lovers. That's why the forums are here!
Shano was simply pointing out what he thought to be a few small problems with you method of conversion, and the fact that the worng DBA part no. was supplied - which is again useful to the toyota community as it promotes thought and investigation, leading to an eventual perfection of the method.
Shit dude, i have had some hair brained ideas as well! and i share them.... but i take what people say to be constructive criticism, i don't take it personally. And i don't think anyone should for that matter
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Location:
Melb, Victoria
Registered:
September 2002
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Re: Superstrut disc straight fit (almost)
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Wed, 18 June 2003 23:33
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| jasonp1977 wrote on Wed, 18 June 2003 15:35 |
How did you machine down the hub?
is the disc an interferance fit over the hub? or is there some room?
Jason
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The hub was machined on a lathe of some sort.
I'm not sure what you mean by an interferance fit, the disc fits over the hub like normal, not pressed, it sits on the outer edge of the hub the same way it would sit on a correct sized center hub.
The Witlz - Constructive criticism is great but it's the tone of Shano's messages that i have a problem with. Others have managed to ask questions without making me feel like i've got no idea at all, i'm happy to answer any of those questions.
Vic.
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: Superstrut disc straight fit (almost)
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Thu, 19 June 2003 02:30
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i understand how you can read the tone of shano's response, however i know the guy in person and can vouch that the way you interpreted the tone is different to how it was intended. It's just the way the guy is
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