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Henn
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Location:
Rosanna, Melb
Registered:
June 2002

How to fit RX7 calipers to an AE86 - Links to pics	Mon, 09 May 2005 10:47

Recently I have been getting regular emails about the RX7 brake setup I have on my Sprinter and so I thought I might write this up once rather than responding individually. The aim was to keep stock struts (whether this is a good idea can be debated) and this is the setup I eventually got to work. Photos thanks to imageshack.us - Brakes from front Brakes from rear showing stepped adaptor Brakes from rear showing more of the adaptor It consists of: Stock strut Stock hub Stock lower control arm and steering arm Calipers- S4 RX7. Some of the fins on the caliper had to be filed to fit them under 15" rims. Plus the lump near where it says MAZDA had to be filed down to clear the wheel spokes... however DONT FILE IT FULLY FLAT otherwise you open a brake line. Leave at least 2-3mm proud. Disc- 280mm 180SX (from SR20 variety I think). Needs to be redrilled to suit stud pattern on the BACK of the sprinter hub. Locator- Custom locator ring so disc fits snugly on AE86 hub. Locator pic Locator drawing Brake mounting plate- Custom. This was the part which took ages to make but it worked in the end. I made them from 450MPa steel although I think you could probably make it from good alloy and it would be strong enough. I've been quoted around $6-700 a pair to machine these adaptors. Pics of adaptor only: 1 2 3 Drawings of adaptor: 1 2 3 4 Models showing fillets on the corners: Front Back And an old page I just dug up where Garth hosted most of these pics a couple of years ago. Thanks for keeping it up. Problems- The main problem I ran into was that if the caliper sat inboard of the spokes of my wheels then the disc rubbed on the lower control arm. My Superlights only have 6-7mm of space between the wheel mounting face and the inside of the spokes. I got around this by running offset roll centre adjusters which pushed the bottom of the strut (and therefore hub and disc) out 17mm. Offset RCA If you plan on doing this upgrade and have more room outboard of your wheel mounting face then you could redesign the adaptor to mount the caliper further outboard. This removes the need for offset RCAs and also makes the adaptor both stronger and easier to machine. This would require a new disc be chosen with the correct offset. I seem to remeber Audi A3 discs were an option. Results- I've used these for almost 18months and they are great. With EBC greenstuffs I have never had them fade even when trying on track (with 110rwkw). In conclusion I wouldn't recommend doing this, it is total overkill and I think there are cheaper and easier upgrades out there. However some of you I'm sure will not be put off (like me) and want the bling of 4piston brakes. If so then good luck and please consider the time and effort I poured into this setup and help me out with a favour some day. Hen [Report message to a moderator]

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