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Manual Brake Conversion: Parts List


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#1 speedyquest

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Posted 05 April 2016 - 10:32 AM

Wilwood Parts:
Wilwood Compact Master Cylinder Kit: 260-10374 = $80.00
Wilwood Adjustable Proportioning Valve: 260-8419 = $45.00
Wilwood Brake Master Clevis: 330-13192 = $16.00

Fragola Fittings:
Tube Nut: FRA-481803-BL X 5 = $1.00 each
Tube Sleeve: FRA-481905-BL X 5 = $1.00 each
3AN to 1/8" NPT Adapter: FRA-481603-BL X 1 = $4.00
3AN to 1/8" NPT 90 Deg: FRA-482203-BL X 1 = $7.00
3AN Tee w/ female swivel: FRA-498201-BL X 1 = $18.00
3AN Tee w/ 1/8" NPT side: FRA-482503-BL X 1 = $8.00

JDL Parts:
Brake Master Adapter Plate (includes hardware) = $40.00

Portfield Parts:
Portfield R4S Front Pads: AP389-R4S = $72.00
Portfield R4S Rear Pads: AP144-R4S = $63.00

Notes:
I used Fragola fittings because I really didn't want to trust no-name fittings, you could save a bit of money if you went with the ebay stuff but I personally wouldn't suggest it.
When you go to order these things remember this is just what I needed for my specific setup and you could plumb this other ways. I figured you guys would appreciate a clear path to follow and a break down of cost so you can decide for yourself if this is right for you.

I'll be updating this as I finish this project. I'll include some pictures and also what I think of the car both with stock pads and the Portfield ones. I'll keep ya posted!

Edited by speedyquest, 05 April 2016 - 10:34 AM.

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=






#2 BC_99

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Posted 05 April 2016 - 10:56 AM

Nice write up. Thank you for taking the time to do this.

BC
Steering coupler replacement U-Joints are available here...
http://www.starquest...howtopic=145280

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#3 speedyquest

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Posted 05 April 2016 - 10:57 AM

No problem at all BC, I see people talking about this semi regularly and I figure maybe if the info is available more people might take the dive lol.

Edited by speedyquest, 05 April 2016 - 10:57 AM.

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#4 psu_Crash

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Posted 05 April 2016 - 11:29 AM

Great stuff Speedy! Looking forward to some pics of the install. Specifically in the engine bay side. If there is already a thread with that .. then I apologize :)
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#5 speedyquest

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Posted 05 April 2016 - 11:33 AM

No need for apology psu_Crash, if you want to see some early pictures I have a few in my build thread. I actually just finished plumbing it last night but it was so dark out I just couldn't take a picture. I'll take some tonight and post them here.

Build Thread --> http://www.starquest...c=143564&st=400

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


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Build Thread --->  http://www.starquest...opic=143564&hl=


#6 Dred_85.5_TSI

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Posted 05 April 2016 - 04:59 PM

Thanks speedy! I'll probably be referencing this when I work on converting my 84. I can't wait to see pics of this setup. Good job :)
Posted Image   1984 Starion ES: Currently running 15psi, Stock block (ARP main and head studs rod bolts, Clevite bearings) BSEK, M28 NJV head with mechanical valve train gasket matched on intake and exhaust, Treadstone exhaust manifold and Holset HX35w with BEP turbine housing, MK1 3" stainless exhaust, Old skool HKS super BOV, 3" GM MAF with MAFT, Artinist's old 4" core intercooler, custom Aluminium hard pipes, S13/SR20 Aluminium radiator w/clutch fan, Innovate LC-1 wide band O2, `83 crank pulley with A/C removed.
   `88 5 speed trans with Stedbani short shifter, Stedbani poly trans mount and engine mounts, drilled and slotted rotors, Joly roger stainless steel braided lines(brake, clutch, oil cooler, and ABS delete).
   KYB GR2, Artinist sleeve coil-overs, MK1 poly bushings, Energy Suspension poly end links, MK1 Adjustable tension rods, Cusco front camber plates, Artinist slotted rear camber plated.
  
ABS, A/C, Cruise control.. deleted, Right hand drive E-brake handle.

... more to come
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#7 speedyquest

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Posted 05 April 2016 - 07:38 PM

Here is a close up of how everything is plumbed on the firewall. After doing this I'm not happy with how everything is ran aesthetically so I'll be redoing it. But mechanically this will work perfectly.

Posted Image

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#8 speedyquest

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Posted 05 April 2016 - 07:40 PM

.... Soooo I literally just posted this picture and immediately noticed I plumbed it wrong. For fun I won't post what's wrong immediately, I'll let you guys take a crack at it first.

I deserve whatever witty jabs you guys feel like sending my way... Ugh

That's what happens when you rush. My only saving grace is I planned on replumbing the whole car after moving it the 6 blocks to my new shop anyway.

Edited by speedyquest, 05 April 2016 - 07:42 PM.

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#9 speedyquest

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Posted 05 April 2016 - 07:45 PM

And just a view to show the difference in space available now.

Posted Image

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#10 importwarrior

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Posted 05 April 2016 - 07:55 PM

great write up. i would like to put this in the FAQ section.

B-71 87 TSI ~ RIP
Black 87 Starion ~ Mess SOLD!!!
Proud New 89 slightly Rusted Fiji Owner !!!

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#11 speedyquest

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Posted 05 April 2016 - 08:07 PM

Feel free importwarrior but wait until I finish it so I can edit it.

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#12 importwarrior

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Posted 05 April 2016 - 08:10 PM

i was just going to copy your first post and your pic and a link to this post so if people have questions thay can post them here.

B-71 87 TSI ~ RIP
Black 87 Starion ~ Mess SOLD!!!
Proud New 89 slightly Rusted Fiji Owner !!!

The Ark was built by amateurs , the Titanic was built by Professionals.


#13 speedyquest

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Posted 05 April 2016 - 08:18 PM

Definitely don't post that picture yet please. Go up and read my post. I plumbed that wrong... LOL

See if you can figure out what I did. I'll post a new picture after I fix my blunder.

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#14 Funky Phil

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Posted 06 April 2016 - 12:51 AM

Looks like the front driverside is gonna go bald.
10.95@122mph MoFuggin stickshift! https://m.youtube.co...h?v=8Q01UKt5q4U

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#15 cyberquest

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Posted 06 April 2016 - 01:07 AM

i love the simplicity of it and the space it frees up, i think i would want to drive one to see how it feels but i like the idea behind it.
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#16 speedyquest

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Posted 06 April 2016 - 07:30 AM

View PostFunky Phil, on 06 April 2016 - 12:51 AM, said:

Looks like the front driverside is gonna go bald.

Ding ding ding we have a winner. I mistakenly plumbed the drivers side front into the rear calipers position. I'll fix that and get a new picture up.

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#17 speedyquest

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Posted 13 April 2016 - 08:23 AM

I can report that the manual brake conversion feels goooood! It was a short drive to the cars new home but in that time I was able to see how it felt at the very least and I'm pleasantly suprised. Because of other people talking about how much manual brakes sucked etc I expected them to not work well at all and to require tons of braking effort and that just was not the case. The cool thing is that the car still has the stock pads installed. Once I get the Portfield race pads on there the brakes are only going to feel better.

@importwarrior: I'll update the pictures when I can so you can do what what you wanted with the info.

Edited by speedyquest, 13 April 2016 - 08:24 AM.

1987 Flatty Starion -- Widebody Conversion -- V-Mount Setup --  JDL Tubular Manifold  --  MX-6 Intake -- MS3-Pro -- AEM FPR  --  ARP head studs -- 3" hood exit exhaust -- Hahn Racecraft 16g --  Tial F38 Wastegate -- Tial Q Bov -- Short route piping -- 5 lug & LSD conversion -- Tubular Front End -- Manual Steering Rack Conversion -- Manual Brake Conversion -- Stack Digital Dash -- AEM UEGO -- D2 coilovers -- full GNT poly bushings & mounts -- four 8" rears -- car lightened significantly...  More to come!


Posted Image


Build Thread --->  http://www.starquest...opic=143564&hl=


#18 importwarrior

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Posted 13 April 2016 - 10:59 AM

ok, no rush.

B-71 87 TSI ~ RIP
Black 87 Starion ~ Mess SOLD!!!
Proud New 89 slightly Rusted Fiji Owner !!!

The Ark was built by amateurs , the Titanic was built by Professionals.


#19 Funky Phil

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Posted 14 April 2016 - 05:48 PM

People were referring to old crap. Some think technology stopped in the 60's when it is blatantly obvious that it wasnt halted until the mid 70's.
10.95@122mph MoFuggin stickshift! https://m.youtube.co...h?v=8Q01UKt5q4U

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#20 cyberquest

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Posted 15 April 2016 - 11:24 AM

i had a mid 80s S10 with manual brakes. i think more important is the fact that cars of the 60s-70s where big old hunks of detroit steel and weighed as much as a delivery truck. i would imagine the light weight of the quest would be a whole lot easier to stop.
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