shift1313 Posted August 21, 2008 Author Report Share Posted August 21, 2008 this conversion is already done here in australia, we use a 282mm nsx rotor and wilwood dynalite calipers, i am in the process of redesigning the caliper bracker because the one used is too big and heavy, same as the drawings at the beginning. will post pics when im done. if you want more info go to www.austarion.com/tech/index.php there's a pdf file there wilth all the specs but the is a discrepancy with the wilwood mounting position its out by 3mm. the bracket mod im doing will be half the size and weight. juice, thats where i got the info from to do this. I drew the bracket myself and found that discrepency. it was .15" too close for the caliper mount. I played around with the drawing and my bracket ended up being 3/8" thick steel. A few pages back you can see the stress distribution files. While you could remove some weight i think the biggest savings would be going to aluminum. Adding extra corners and things are just going to give locations for stress risers. Id like to see what you come up with though. Link to comment Share on other sites More sharing options...
shift1313 Posted September 4, 2008 Author Report Share Posted September 4, 2008 I just wanted to post a little update. For the past few days in my spare time I have been working on an extensive analysis of the starion braking forces. Im not taking into account engine braking or wind resistance but i have a lot of calculations on forces, braking distance, weight transfer etc. Im trying to come up with a very accurate model of the car mathematically that will let me know how safe my bracket it and what design changes need to be made. Since the bracket was the "cheap" part of the whole conversion I have the ability to play around with things. I have been over on austarion talking to juice about it and it sounds like hes got a good source working on this for/with him. Im not really looking to lighten the bracket but i want to make sure the design is sound. My design was based on some assumptions I made from a few calculations, but i just want a bit more. Right now i have one of my professors(who wrote the dynamics text book we use and is a car guy) looking over my work and im waiting for some insight. Once i get my results i will post all the math here if anyone cares or is interested... Link to comment Share on other sites More sharing options...
85_technica Posted September 9, 2008 Report Share Posted September 9, 2008 was browsing the austarion site and came across this little quote. " For what its worth, my rear setup is using a early model MR2 front rotor (re-drilled to 4 stud) with 4 piston calipers (3/4") and a custom made mounting bracket. The fronts are NSX with 4 piston calipers with 1" pistons. Balance bar adjustment (F/R Bias) including in cabin adjustment and a Willwood pedal box. No brake booster. They work well. Wink" another guy mentioned a bolt on brembo rear caliper and also rx7 front rotors/spindle setup [imghttp://i214.photobucket.com/albums/cc219/silobin/100_0240.jpg[/img] http://i214.photobucket.com/albums/cc219/silobin/100_0236.jpg he said brakes were evo 6 stuff here is more of his car http://forums.austarion.com/viewtopic.php?t=9942 Your upgradeing to my rx7's stock brakes =] Link to comment Share on other sites More sharing options...
shift1313 Posted September 9, 2008 Author Report Share Posted September 9, 2008 haha not quite, i think that would be a downgrade for me;). Link to comment Share on other sites More sharing options...
85_technica Posted September 9, 2008 Report Share Posted September 9, 2008 haha not quite, i think that would be a downgrade for me;). Weak sauce =[ Link to comment Share on other sites More sharing options...
shift1313 Posted September 21, 2008 Author Report Share Posted September 21, 2008 playing around with cad and the car front ends i drew a rotor and 6piston caliper, thought id toss it in here:) http://i268.photobucket.com/albums/jj39/shift1313/Starion/Cad%20Model/RotorRender.jpg i have a set of crown vic rotors that should work for a 5lug upgrade. when i get the time ill start mocking that up for those who are interested. Link to comment Share on other sites More sharing options...
Casey_L Posted September 23, 2008 Report Share Posted September 23, 2008 Nice Matt. I am going to pick up a wide body front strut from the junkyard on Sat to take some measurements and hopefully mock up a setup using crown vic rotors and Sumitomo 4-piston calipers. I might be picking your brain soon again in the new coming weeks. Link to comment Share on other sites More sharing options...
shift1313 Posted September 23, 2008 Author Report Share Posted September 23, 2008 sounds great casey, are you grabbing the strut so you dont have to pull your stuff off? Link to comment Share on other sites More sharing options...
Casey_L Posted September 23, 2008 Report Share Posted September 23, 2008 Yeah, my car is my daily and I don't want to tear things apart just to put it back together while I am in school. I am also going to pick up a Starion crossmember. I will keep you updated. Link to comment Share on other sites More sharing options...
shift1313 Posted September 23, 2008 Author Report Share Posted September 23, 2008 i wasnt sure since your sig said project car next to it:) Link to comment Share on other sites More sharing options...
Casey_L Posted September 23, 2008 Report Share Posted September 23, 2008 I don't know what my car is now. lol. Link to comment Share on other sites More sharing options...
shift1313 Posted September 28, 2008 Author Report Share Posted September 28, 2008 Here are some pics of the crown vic 5lug stuff im working on. the 98-02 vic had the most offset(still about 1/8" shy of the 5lug rotors) and the OD is 12 29/64. Because the offset is a little less on these rotors to get them to work with the stock 16" rim there will have to be a wheel spacer. I havent measured everything yet but i would imagine at least 1/4" if not a bit more to clear a stock style single piston floating caliper. And no the stock calipers wont work, they arent wide enough, but in the pics i have a stock caliper with no pads. Its really hard to see in the pic but the caliper is touching the rim(just barely). Its free enough for me to rotate it but i would never run a caliper that tight. Im going to look into other single piston floating caliper options as well as 300zx and mock something up with my wilwoods but its not looking good for stock 16" rims with these rotors so far. Ill update this thread as i get more time to work on it(which wont be much). http://i268.photobucket.com/albums/jj39/shift1313/Starion/5lug%20brake%20upgrade/widebodybrakeUG.jpg http://i268.photobucket.com/albums/jj39/shift1313/Starion/5lug%20brake%20upgrade/widebodybrakeUG2.jpg http://i268.photobucket.com/albums/jj39/shift1313/Starion/5lug%20brake%20upgrade/widebodybrakeUG3.jpg http://i268.photobucket.com/albums/jj39/shift1313/Starion/5lug%20brake%20upgrade/widebodybrakeUG4.jpg http://i268.photobucket.com/albums/jj39/shift1313/Starion/5lug%20brake%20upgrade/widebodybrakeUG5.jpg http://i268.photobucket.com/albums/jj39/shift1313/Starion/5lug%20brake%20upgrade/widebodybrakeUG6.jpg Link to comment Share on other sites More sharing options...
Casey_L Posted September 29, 2008 Report Share Posted September 29, 2008 A disc from a 2000 ford explorer sport track is another 12" rotor to look into. I am going to try and use that rotor because I am buying it anyways to do a WJ Grand Cherokee akebono caliper retrofit on my ZJ Grand Cherokee. I got my starion front cross member, LCA, and strut assembly from the junkyard. (as well as WJ brake components). Ill let you know how that rotor turns out. Link to comment Share on other sites More sharing options...
shift1313 Posted September 29, 2008 Author Report Share Posted September 29, 2008 (edited) here is the total height spec on the rotors. 2 39/64 height explorer sport trac 2 37/64 height crown vic i did find something interesting, 2wd explorer sport trac rotors are 12" and have a 4 1/4 total height! and so you know sport and sport trac 4wd versions have the same rotors. let us know how it works out for you. also im sure you already know this but the wjs had problems between 99-02 with the front calipers sticking and warping rotors with the teves calipers and the akebono stuff didnt start until the end of the 2002 model year, if you are looking for used stuff. Edited September 29, 2008 by shift1313 Link to comment Share on other sites More sharing options...
FijiPhil Posted September 29, 2008 Report Share Posted September 29, 2008 Thats not good news matt Link to comment Share on other sites More sharing options...
shift1313 Posted September 29, 2008 Author Report Share Posted September 29, 2008 well maybe the 12" sportrac rotors will work. they will fit into a stock 16" just fine. I think i can make these fit with spacers phil, but i just dont know yet:) Link to comment Share on other sites More sharing options...
FijiPhil Posted September 30, 2008 Report Share Posted September 30, 2008 well maybe the 12" sportrac rotors will work. they will fit into a stock 16" just fine. I think i can make these fit with spacers phil, but i just dont know yet:) good stuff! Link to comment Share on other sites More sharing options...
Casey_L Posted October 1, 2008 Report Share Posted October 1, 2008 I have been playing around with the idea of big brakes and a rack and pinion setup. If you want to do both I think the starion/240 hybrid cross member method is the best. That way you can run 3000GT calipers on the 240sx knuckles, and upgrade the hubs to 5x4.5. Like DJpowerhaus. Link to comment Share on other sites More sharing options...
shift1313 Posted October 1, 2008 Author Report Share Posted October 1, 2008 stock 5 lug hubs are 5x4.5. are you talking about converting the flatty 4 lug over? I plan on addressing rack/pin and suspension at a later point when i get the time. Id like to do airbags on all 4 corners but i dont know yet. Link to comment Share on other sites More sharing options...
shift1313 Posted October 23, 2008 Author Report Share Posted October 23, 2008 i was playing around today at work and put some numbers on this drawing in case anyone wanted it. I dont think i posted any numbers yet. http://i268.photobucket.com/albums/jj39/shift1313/Starion/Brake%20Conversion/brake2.jpg There should be enough info to create the bracket for your own there. the 3 holes in the center are 120degrees apart so you have enough info there even though there arent any numbers. Link to comment Share on other sites More sharing options...
shift1313 Posted March 22, 2009 Author Report Share Posted March 22, 2009 i just happened to be browsing the wilwood site looking for ford 9" rear disc setups and thought id check out their rotor hats and see if anything changed. I came across two hats, one that might work for the 5 lug and one that might work for the 4 lug. This would open up a lot of options. 8 x 7.00" 4 x 4.50" 0.72" .50" 2.72" .25" 5.90" 5/16-18 170-6996 230-8390 8 x 7.00" 5 x 4.50/4.75" 1.43" .52" 3.00" .25" 6.04" 5/16-18 170-7632 230-3484 the titles wont copy over well but here they are Rotor Bolt Circle Wheel Lug Pattern Hat Offset Stud Hole Diameter Center Hole I.D. Face Thickness Clearence I.D. Mount Hole Hat Part Number Rotor Bolt Kit Number I also noticed they make un-drilled hats. Link to comment Share on other sites More sharing options...
AUSSIEOLDIE Posted May 21, 2009 Report Share Posted May 21, 2009 My Flatty has 300mm Evo discs and 4 pot nissan calipers and will justfit under stock 15s and easily under my ultralites Has anyone any ideas on how to improve the handbrake to get more power/grip ???????? Link to comment Share on other sites More sharing options...
shift1313 Posted May 23, 2009 Author Report Share Posted May 23, 2009 do you have any pictures of that? the 11.1" rotors i used with the dynalite calipers barely has any clearance. Id like to know what nissan calipers let you squeeze an extra 3/4" rotor in there and how tight the clearance is. What are you looking to do with the handbrake? have you considered two extra calipers, either cable or hyd. you could run a remote master for just the hand brake. Link to comment Share on other sites More sharing options...
AUSSIEOLDIE Posted May 23, 2009 Report Share Posted May 23, 2009 do you have any pictures of that? the 11.1" rotors i used with the dynalite calipers barely has any clearance. Id like to know what nissan calipers let you squeeze an extra 3/4" rotor in there and how tight the clearance is. What are you looking to do with the handbrake? have you considered two extra calipers, either cable or hyd. you could run a remote master for just the hand brake. My big brake setup was done by a brake specialist and "blue plated" = engineered & road legal. i can tell you that the mounting plate is nothing like the pics here& it bolts up to the stock caliper mounts and there is an app 4mm spacer that goes on the spindle/axle to get clearance for the rod end. Clearence with the stock 15's is very very small but aftermarket 15's have much more space. The Nissan calipers are 300zx + a Willwood bias adjuster. Works extremely well hauling it down from 220 kph's app 135 mph on the track I like your idea about the handbrake and will discuss it with my engineer Will have to learn how to post pics Cheers Rad Link to comment Share on other sites More sharing options...
Lunacy Posted May 24, 2009 Report Share Posted May 24, 2009 Rad if you send me the pics il host them for you mate Link to comment Share on other sites More sharing options...
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