Evo twin spot front brake conversion

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Callumgw
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Joined: Fri Aug 11, 2006 12:55 pm
Location: Melbourne, Australia

Evo twin spot front brake conversion

Post by Callumgw » Fri Feb 06, 2009 6:29 pm

CAUTION: playing with your brakes is dangerous. Do it at your own risk, better still only do it on a track car.


GENERAL DESCRIPTION

Firstly, the new brake disc is located to the outside of the hub, not the inside. So as you can see from the black/red hashed section below we do need to have the hub machined.
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The calliper is also not a perfect fit and needs to have the hole enlarged and pulled slightly to work;
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Other than that its fairly simple and the results fit under a 15 inch wheel.

REQUIRED PARTS:
Akebono twin piston Calliper (as fitted on Mitsubishis) from:
some EVO 1
all EVO 2, 3, 4
some EVO 5, 6
some Pajero 91 - 2000 (NH, NJ, NK, NL)
some Magna TH and TJ
all Verada 1992-2000

Brake Pads:
Bendix Number: DB1223
TRW/Lucas: GDB1126

Disc Rotors:
Galant HH5 VR4 Turbo DBA402 (vented 276mm diam 24mm thick)

Brake lines:
Stock ET/Exa or Custom.

Wheel Studs
N13 Pulsar and others (Nice Products S457) 4.5mm longer to help account for the relocated disc

For info here is a parts brake down for the calliper:
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The Mitsubishi part number for the clips (51140 in the image) is: MR389599
The Mitsubishi part number for the shims (51150 in the image) is: AW350280

MODIFICATION PROCEDURE:

remove the standard hubs:
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Separated:
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New ones and old ones:
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Enlarge and slightly offset this hole:
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it needs to be enlarged to take a 12mm raised shank on the bolt, like this:
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Trial fit the caliper looks like:
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This picture above has the standard ET brake line mounted to the caliper.


Then machine down the outer diameter of the hub so the VR4 disk fits to the outside.
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This is inside a standard 15x5.5 inch TRX rim, No bearings installed:
With just the carrier:
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With calliper as well:
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I found the calliper carrier did not sit evenly over the disk:
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so a simple washer as a spacer:
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and it's perfect:
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When inside the TRX rims the from face of the calliper just touches the inside of the rim, not enough to stop turning, just enough to rub. one washer thickness stops this, so I'll be getting and using a 3mm spacer. A different rim may not have this issue.

Installing longer studs might be required. I used the N13 studs which are 8mm longer. This should account for the disk being on the outside of the hub and the spacer.

Refit to the car
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Standard brake lines will bolt up, but custom braided ones are better and should be made with anti-loosening that the standard ones wont have when fitted on these callipers. The images earlier have a standard ET brake line bolted on. I had custom lines made up in ADR approved braid. It was done by Nigel (0488793303) from a mobile brake line company (http://www.mobileautohoses.com.au/). Highly recommend his work and he kept all the details so if you ring him and tell your putting EVO brakes on a N12 Exa/Pulsar he'll be able to mail you the right lines.

Note: he can also make rear lines for the ET, but needs to know whether the rear solid lines have a double flare or single flare. It seems the ET and Exa/NA are different. ET had double flare and Exa had single flare - so check and be sure.

4 lines (front and rear) $380 or $190 front pair.
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Calliper mount
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Mid support
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Wheel well mount
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ADR Braid:
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Mounted:
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SUBSCRIPT
Heres a compare of the various pad sizes:
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Pad..........Pad Areas...% increase over Stock....% less than Evo.........Notes

DB293.......1750059................100.0.........................57.7.....................N12
DB225.......2118007................121.0.........................69.8.....................Prairie
DB1117.....2043692................116.8.........................67.3.....................N13
DB319.......2832770................161.9.........................93.3.....................Magna TN (tapered tabs excluded)
DB1223.....3034578................173.4.........................100.0...................Evo


C
Last edited by Callumgw on Tue Sep 01, 2009 7:49 am, edited 13 times in total.

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