Rally's MY04 Forrie- Poverty Pack special

Purchased second hand. Rear diff and instrument cluster replaced under warranty. First change was to fit CB UHF GME radio. Car has externally mounted windscreen aerial bracket. Just purchased set of new KYB shock absorbers- the originals have had it- will install when they arrive. Next step is to replace standard steel rims with MY99 WRX rims. Then sump guard and driving lights.

 

[Rally]

No. They miss by a few mm- close, but not too close with 215 tyres.

 

[Hunter]

Cheers, I just picked up a set of 4 black ones from eBay for 150.

The poverty pack is looking good too mate!

 

[Rally]

Not for the Forrie, but the Impreza. Now for some serious stopping power. 8 piston front callipers on bigger and beefier 2 piece discs.

 

[Ratbag]

Look good, Rally.

Do they work ... :rotfl:

 

[Rally]

It was a bit of a drama. With the diffs the car has, you cannot free spin the front wheels like you can on most Subaru's- unless you jack the whole car up. So having installed the brakes and bled them, I went for a test drive. There was a horrible scraping noise. I realised that it had to be the disc rubbing something as it was happening with or without the brakes applied. Ripped off the callipers and the disc and saw scoring marks on the disc. I noticed that the bracket bolts were marked, meaning that they were too long. So I whipped out the angle grinder and ground them off. Put it all back together, but the noise was still there. ??? And now the ABS light was on. So I took the brakes off again and notice the heat shield was also marked. I had a suspicion that the metal filings from grinding away the bolts had being attracted to the ABS sensor. Sure enough, it was covered in metal filings so I quickly removed them- and the heat shield- on both sides. I re-installed the ABS sensors but not the heat shields, re-assembled the brakes and the noise was gone and so was the ABS light. Pads are not bedded in yet.

 

[mr turbo]

Now thats what I call stopping power

Very nice Rally

Regards
Mr Turbo

 

[Ratbag]

Oh dear!! Doesn't that sort of thing give you the *****!

Don't you need the heat shields to protect the flexible brake hoses?

Do they have any effect on air flow over the discs?
After all, a brake works by converting the kinetic energy of the car into heat, which the brakes have to radiate away. Brake fade being caused by the disc (or drum) not being able to dissipate the heat in it, so the braking effect vanishes. Had a very bad experience coming down from the Lamington Plateau in a disc braked HR Holden on one memorable occasion some 40+ years ago ... Half way down the very long hill, the brakes faded to nothing. A two speed slushbox wasn't much help, either ...

 

[Rally]

No, the brake shields are one of the first thing track guys remove from the car. They do help protect the rubber in the tie rod end, so some protection is required there. Heat shields reduce cooling to that side of the disc. The brake lines aren't affected- besides, the fluid they have in them is subject to the heat from the pistons and pads, and that is a much better conductor of heat than air. I 'm pretty sure the protection of the tie rod boot can be solved. HR Holden discs are about half the size, with 1/8 the number of pistons and pads of much older technology. And the HR only had 2 discs.

 

[Ratbag]

Mate, the HR brakes were completely flaming tragic!

The body also had the torsional rigidity of a piece of wet spaghetti, slightly more than that of the Valiant of the times at between 6,000 and 7,000 ft.lbs. per degree torque to bend it one degree out of alignment. At least the HR would twist and then resume its correct shape. The V8 Valiants could twist if accelerated very hard out of a corner, and could not be straightened properly, even using a Mayrack ... By comparison, an Austin 1800/Kimberley took 15,800 ft.lbs. per degree ... Just a tad stronger, and more rigid ...

My Morris 1100 would stop from 60 mph in around 132 feet; and in a straight line ... The HR was around the 175-185 feet mark (IIRC). Bloody hopeless!

Glad your new brakes will be so good - just pulling your leg before . I am sure you will work out a way of protecting what needs to be protected. Bigger, better designed brakes should also generate less heat for the same performance.

 

[Rally]

Well, at least the HR was better off than the HD! 4 little coconut shells with a thin line of asbestos waiting to do very little. DId you see the photo Wheels did of a Holden back then of it's emergency braking? The axle tramp was so severe you could see quite clearly when the wheel was in the air and when it was locked leaving the intermittent skid mark. The caption read, "Cut across the dotted line"!

 

[Kevin]

Beautiful brakes Rally - remind me, what is your address? :lol:

 

[Rally]

1300 Anzac Parade Matraville NSW and stay for dinner and overnight boarding.

 

[Kevin]

Well I drove by - I think someone stole your car!

 

[Rally]

Why didn't you pop in and stay a while?

 

[Kevin]

It may have finished up being a "long stay" :lol:

 

[Rally]

For those who don't get this, that address is for Long Bay Gaol, one of the major NSW gaols. I know Kevin is an honourable man, so I won't ask him how he knows!

 

[NachaLuva]

Now for some serious stopping power. 8 piston front callipers on bigger and beefier 2 piece discs.

Whoa! That is serious! I dont think I've ever seen 8 pots before

What are 2 piece discs? Never heard of that before either...The disc itself is 1-piece & bolts to the centre part thingy (cant think of the name for it lol)?

Beautiful brakes Rally - remind me, what is your address? :lol:

1300 Anzac Parade Matraville NSW and stay for dinner and overnight boarding.

For those who don't get this, that address is for Long Bay Gaol, one of the major NSW gaols. I know Kevin is an honourable man, so I won't ask him how he knows!

I wont ask how YOU know either lol :rotfl:

I must admit I was VERY surprised you posted "your" address till I googled it with a fair amount of suspicion haha :rotfl:

Awesome setup Rally, was just admiring Venoms 4 pots yesterday...you've set a whole new benchmark

BTW, what diffs do you have. I think you have the DCCD....what front & back?

 

[Rally]

2 piece discs- the disc itself is cast iron, and it is bolted to an aluminium hat. The aluminium hat has far better heat transfer properties than cast iron, which is what normal one piece discs are made from.

I looked up the address for Long Bay Gaol on the internet before posting. I thought it might surprise people at least initially!

8 pots is probably a bit of an overkill for my use- it's just how they come in that size. You'd be amazed what's out there though. 416mm discs, 16 pot callipers. The beauty of this set up I have is that it can be used with standard WRX rims, whereas Brembos requires certain rims for clearance.

I run a helical front diff, DCCD and plated rear diff in the WRX. The Forester is also getting an upgrade, with plated rear diff and helical front diff as well. I've bought the diffs- they just need to be installed. The front diff wil be interesting. It's from an 06 STI and if it all works out as planned (pioneering work this) it will probably be one of the first or only times a 6 speed front diff has been installed into a dual range 5 speed. Of course, it may not fit at all, but such is life. Live and learn.

 

[Kevin]

I know Kevin is an honourable man, so I won't ask him how he knows!

No big mystery really - played in the resident rock band at South Sydney Juniors 4 nights a week for 7 months many many moons ago and, as you do, also partied considerably in the area!

Some understanding of Rally's sense of humour also helps!

 

[mr turbo]

I must admit I was VERY surprised you posted "your" address till I googled it with a fair amount of suspicion haha :rotfl:

I looked up the address for Long Bay Gaol on the internet before posting. I thought it might surprise people at least initially!

I almost crapped myself when I first saw it too & was going to edit it (address) out
But then the penny dropped

I won't ask how you know either but I have to admit I did enter that establishment once or twice some years ago.

It was all good though, as I used to be a courier & had a few deliveries (stationary supplies etc that is) to drop off at the time as part of my job

Regards
Mr Turbo