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Guest Message by DevFuse
 

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*teaser* rear EJ brakes on EA car..


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25 replies to this topic

#1 PoorManzImpreza

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Posted 03 March 2009 - 10:05 AM

Much much more to come, but here are my teaser pics of 2003 JDM wrx twin piston (two pot) brakes on my 1989 'L-series' using my custom and hand fabricated (HIGHLY recommend having them machined!) adaptor plates:
Posted Image
Posted Image

Kaz

#2 The Scooby

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Posted 03 March 2009 - 11:18 AM

i can't wait to see the write up on this as well as the specs, i wouldn't mind doing that rear upgrade as well as the fronts.

#3 Jerry DeMoss

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Posted 03 March 2009 - 01:26 PM

Do you have a picture of the adapter plate?

#4 bratman18

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Posted 03 March 2009 - 01:28 PM

yes details!! Does this mean it's still all EA components and you were able adapt the 5 lug and brakes?

#5 carfreak85

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Posted 03 March 2009 - 03:00 PM

Where is that huge dancing banana when you need him? Here's his little cousin... :banana:

#6 Numbchux

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Posted 03 March 2009 - 04:59 PM

looks like pretty much the exact same thing that rguyver did with his brat a couple years ago. XT6 hubs, and EJ backing plates adapted to the EA trailing arms.

#7 SubaruJawn

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Posted 03 March 2009 - 08:12 PM

hunh. i should do this with my ea car
i have the EJ Rear Everything.

that the XT6 hub ? or is that the EJ rear Hub ?

#8 Quidam

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Posted 03 March 2009 - 08:22 PM

So who wants to machine some adaptor plates up? Kaz get a royalty:)

#9 monstaru

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Posted 04 March 2009 - 12:26 AM

i believe that guyver had a few set of plates previously. but do not think it would be that hard if my memory serves me.search my friends,search......cheers, brian

#10 Numbchux

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Posted 04 March 2009 - 12:46 AM

yea, rguyver "just" welded a ring on the inside of the EJ backing plates to make the center hole smaller, then drilled the 3 holes. Kaz made an adapter.


not exactly ground-breaking stuff, but definitely pretty cool.



my concern is the offset. rguyver found that the rotor offset was perfect the way he did it, by putting an adapter plate between the trailing arm and backing plate pushes it out, which will screw up the spacing between it and the hub face. I suppose you could throw a spacer of the same thickness between the hub face and rotor. but that would push the whole wheel out, which will change how the tire fits in the wheel well (depending on the wheel offset, that could be good or bad).



long story short, I'm anxious to see how this turns out.

#11 PoorManzImpreza

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Posted 04 March 2009 - 02:04 AM

I typed a nice long paragraph and lost it to crappy 'net..:mad: :-\
Anyway, just to clarify:
4wd EA car with ER/XT6 rear hub unaltered
EJ backing plate, handbrake setup, rotor and caliper.

Rguyver used an r180 setup on his brat, for those that don't know the r180 STI setup has bigger diff, axles and hubs thus the backing plate centering hole is bigger than r160. The r180 hole is bigger than the bolt pattern for EA/ER hubs thus rguyver simply welded a ring inside the r180 backing plate with the ea pattern drilled into it and bolted the assembly up.
R160 backing plate center hole is a hair over 10mm larger in diameter than the ea/er mounting hole, thus the ea holes have to be drilled into the ej r160 backing plate.

Th ej backing plate fits flush to the EA hub/trailing arm, there is no spacer between them. What I have done is simply made a ring with ea inner diameter and ejr160 outer diameter that makes up the difference in diameter as well as a plate that sits outside the ej backing plate.

These are the full dimensions of what I fabricated minus one alteration I did when I actually went to put averything together and forgot that I needed to make room for the movement of the lever that controls the handbrake shoes:
Posted Image

There were a few things I wanted to acheive:
Reversibilty: If at some point I ever dump my car and went ej any alteration I did to the r160 backing plate couldn't prevent it from being returned to an ej car

Safety: Must be as safe as stock

No welding

Must be able to fabricate with simple electrical/hand tools (...who was I foolin'?)

No unblocked holes in the ej backing plate: This explains the unusual shape of the adaptor plate

Must be compatible with an ABS backing plate, crossbred kit is NOT (no you still can't mount and ej abs sensor)

and finally Must be freely availible to all who are as insane as I am:lol:

The prototype is made of 6mm aluminium. I will update here with the actual method and more pics (Please, Sis, can I borrow your camera again?) as well as complete DXF files and DWG for those that desire to do the smart thing and take the damn design to their nearest cnc water/laser/3 axis machine and have it do in seconds what I did with my hands a jig saw a drill press and a bench grinder..

damn anyone actually gonna read all that?;)
Kaz

Edited by PoorManzImpreza, 06 March 2009 - 08:38 AM.


#12 grossgary

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Posted 04 March 2009 - 02:16 AM

Dude Kaz - nice work!
yeah, i read through it all, that's awesome.
thanks for sharing, that's excellent work and info there.

#13 rguyver

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Posted 05 March 2009 - 09:30 PM

Good job man ! :banana:

I also made the EJ E brakes work too , i used the EJ handle and cables , ill post pics if interested .

Edited by rguyver, 05 March 2009 - 09:32 PM.


#14 Numbchux

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Posted 05 March 2009 - 10:21 PM

Good job man ! :banana:

I also made the EJ E brakes work too , i used the EJ handle and cables , ill post pics if interested .


I'd really appreciate it if you'd re-post the pictures of your project. as the ones you posted before were in the old gallery, and are no longer there.

#15 Jerry DeMoss

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Posted 06 March 2009 - 12:10 AM

Wow! I am actually a bit blown away, I really want to learn more.:slobber:

#16 Kostamojen

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Posted 07 March 2009 - 08:53 PM

Brembos!!!

I so wish I could do that with my ff-1...

#17 rguyver

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Posted 09 March 2009 - 07:27 PM

ill have to take new pics lost the old ones

#18 kingbobdole

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Posted 09 March 2009 - 11:17 PM

Sweet... so if I use the H6 290mm setup I have laying around, my rear brakes will be bigger then my front!:grin:

#19 kirzick

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Posted 25 September 2014 - 12:46 AM

Can you update this please I could really use the info. Thanks!

#20 Ibreakstuff

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Posted 26 September 2014 - 08:55 PM

Here how I did mine, plasma cut and welded in a EA (these were XT but any work) rear backing plate inner ring and mounting holes to an EJ backing plate. If you do it this way, be careful to clock the backing plate correct so the handbrake cable doesn't hit the trailing arm. Also, make sure you weld the back side flush, the plates have slighting different thickness.. EA plate was thicker iirc. I used the handbrake and entire brake assembly from an 07 OBS. Sorry for the bad picture of handbrake mounting but you get the idea.. Didn't get a picture of it finished, the car was totaled later..

Edit: The machined ring like Nico did it would be the preferred method tho and doesn't waste a EA backing plate. The ring dimensions are shown in the post by PoorManzImpreza.
 

img0367mn.jpg
 

img0373uva.jpg
img0375pz.jpg


img0331t.jpg


Edited by Ibreakstuff, 26 September 2014 - 09:54 PM.


#21 coronan

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Posted 07 October 2014 - 03:06 PM

Is the XT hub special? Can i use any EA82T rear disk hub?

 

What did you use for a rear hand brake cable?



#22 Ibreakstuff

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Posted 07 October 2014 - 03:37 PM

Is the XT hub special? Can i use any EA82T rear disk hub?

 

What did you use for a rear hand brake cable?

 

The XT6 rear hubs are the missing link, you will need 2 of them no matter what parts are used for the 5 lug swap. Those hubs are compatible with any EA82 4WD trailing arm. EA82T hubs are only 4 lug.

I used the entire brake assembly from an 07 OBS (GD Impreza) but any subaru rear disc bits should fit fine. To save yourself the trouble of researching brake parts, you can just use the rear backing plates/calipers/brake rotors/e-brake assemblies from the same car.


Edited by Ibreakstuff, 07 October 2014 - 03:39 PM.


#23 coronan

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Posted 07 October 2014 - 07:20 PM

So i CAN use EA82T parts if i want to stay 4 lug. (which i will take to 6 lug.)

 

How did you run your parking brake cable????



#24 Ibreakstuff

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Posted 07 October 2014 - 07:53 PM

So i CAN use EA82T parts if i want to stay 4 lug. (which i will take to 6 lug.)

 

How did you run your parking brake cable????

 

Well, EA82T bits doesn't have the inner ebrake assembly. You *might* be able to get away with a early EJ backing plate/ebrake assembly and a EA hub/caliper/brake rotor but I have never attempted this before.

Drill holes in the chassis, there are 2 layers of sheet metal you will have to drill through.. Stepper bit works best because they are so short. There is a flat spot on both sides right where you want it. Then run the ebrake cable above the rear sub-frame into the cabin where they would normally go in a later model car. I also filled the void between the sheet metal with foam insulation, added grommets, and painted it on both sides.


This is the only picture I have, not the best.. Note the bracket holes were not drilled and bolted down yet. 

img0376kr.jpg


Edited by Ibreakstuff, 07 October 2014 - 07:58 PM.


#25 Numbchux

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Posted 07 October 2014 - 08:00 PM

So i CAN use EA82T parts if i want to stay 4 lug. (which i will take to 6 lug.)

 

How did you run your parking brake cable????

 

The 4-lug brake setup is completely different. The brake and suspension upgrade options for 4-lug, are convert to 5-lug. If you want to stay 4-lug, you'll have to be creative.

 

 

 

As for routing. I had them go down through the tunnel just like on an EJ car. It wasn't hard, I just used a hole saw, and then cut out between the holes with a cutoff wheel.

 

 

BUT. It should be mentioned, that I had issues with the cables rubbing on the driveshaft. Now, I had a one-piece shaft (car was a FWD car), so this may not be an issue with a stock 2-piece...but make sure you've got adequate clearance. If I were to do it again, I'd drill through the vertical bulkhead just behind this and go through there.....


Edited by Numbchux, 07 October 2014 - 08:04 PM.





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