Another ZZE122R brake upgrade

[CHA54]

Hi Guys,

I did a bit of test fitting this afternoon and have figured out another twin-piston brake upgrade for the ZZE's.

It consists of ST202 celica twin piston calipers and discs, discs require drilling 3 new pcd holes to make it 4x100 then the outside diameter of the disc requires machining down to ~260mm. This gives you a 260x28mm disc, plenty of meat to soak up the heat before they warp at the track.

will post pics after I give the calipers a coat of paint

Jason.

[Blind Kid Seeks]

calipers just bolt up?

[CHA54]

calipers just bolt up?

Yes, 130mm bolt spacing

[SIMPLEROLLA]

Be very careful on what you do on disc rotors as they tend to crack on the weakest point especially from hot to cold instantly like when it rains. Ive seen it happened a couple of times already and the latest one was just this morning and it was cracked where the mounting holes were and this one hasnt been redrilled some extra holes.

[MR22ZZ]

nice work Jason

I already knew they bolted up but was worried about the rotor thickness of all the off the shelf options.

machining down makes this similar to the superstrut conversion with ST185 rotors

another thing worth pointing out though in relation to the ST202 brakes is that they are freaking heavy compared to the standard ones if undamped mass is a concern for you.

[CHA54]

Be very careful on what you do on disc rotors as they tend to crack on the weakest point especially from hot to cold instantly like when it rains. Ive seen it happened a couple of times already and the latest one was just this morning and it was cracked where the mounting holes were and this one hasnt been redrilled some extra holes.

They must be garbage rotors if they crack at the mounting holes. There's very little stress on the rotors at the actual mounting hole locations if you've torqued your wheel nuts correctly.

[SIMPLEROLLA]

Be very careful on what you do on disc rotors as they tend to crack on the weakest point especially from hot to cold instantly like when it rains. Ive seen it happened a couple of times already and the latest one was just this morning and it was cracked where the mounting holes were and this one hasnt been redrilled some extra holes.

They must be garbage rotors if they crack at the mounting holes. There's very little stress on the rotors at the actual mounting hole locations if you've torqued your wheel nuts correctly.

The one I saw on the road the other day was from a volvo s60 (still the original rotors w/ 20ks on the clock). Others I saw was from a Tarago, E46 BMW, Redrilled same as u from an R33 GTR and R32 GTR(they were actually brothers that the disc basically cracked a day after the R33) and the last one was from a JEEP CHEROKEE 97 w/ drums cracked.

Find the nearest size you want to do it properly. Its not worth taking the risk.

Another thing you can do is go to Silverwater if your in sydney and talk to the guys at DBA as they got spec sheets that is not written on the catalogue that spare parts shop.

[CHA54]

Be very careful on what you do on disc rotors as they tend to crack on the weakest point especially from hot to cold instantly like when it rains. Ive seen it happened a couple of times already and the latest one was just this morning and it was cracked where the mounting holes were and this one hasnt been redrilled some extra holes.

They must be garbage rotors if they crack at the mounting holes. There's very little stress on the rotors at the actual mounting hole locations if you've torqued your wheel nuts correctly.

The one I saw on the road the other day was from a volvo s60 (still the original rotors w/ 20ks on the clock). Others I saw was from a Tarago, E46 BMW, Redrilled same as u from an R33 GTR and R32 GTR(they were actually brothers that the disc basically cracked a day after the R33) and the last one was from a JEEP CHEROKEE 97 w/ drums cracked.

Find the nearest size you want to do it properly. Its not worth taking the risk.

Another thing you can do is go to Silverwater if your in sydney and talk to the guys at DBA as they got spec sheets that is not written on the catalogue that spare parts shop.

I wouldn't risk modifying DBA's discs now they source many of their range from TW. Myself and others have done the same mods over the last 10 years on MANY corolla's with a lot of those seeing track work (using custom DS2500 pads, cut down from an evo pad or SW20 turbo Greenstuff pads) with zero issues. Most were doing using brembo discs or the old Aus made DBA's, quite a few with genuine toyota discs too when they were in good condition (AE101 superstrut discs, 275x25mm). The majority of the disc modifications were done by Kevin at St Mary's Specialised Brake and Clutch after consulting DBA directly. My Mrs's daily driver still has the same style upgrade with turned-down brembo 5x100 discs redrilled to 4x100, they've clocked up 40,000km now with zero issues and were engineered in Sydney and are also now modplated in Brisbane. The engineers saw no issue with the structural integrity of the modified discs.

[SIMPLEROLLA]

Be very careful on what you do on disc rotors as they tend to crack on the weakest point especially from hot to cold instantly like when it rains. Ive seen it happened a couple of times already and the latest one was just this morning and it was cracked where the mounting holes were and this one hasnt been redrilled some extra holes.

They must be garbage rotors if they crack at the mounting holes. There's very little stress on the rotors at the actual mounting hole locations if you've torqued your wheel nuts correctly.

The one I saw on the road the other day was from a volvo s60 (still the original rotors w/ 20ks on the clock). Others I saw was from a Tarago, E46 BMW, Redrilled same as u from an R33 GTR and R32 GTR(they were actually brothers that the disc basically cracked a day after the R33) and the last one was from a JEEP CHEROKEE 97 w/ drums cracked.

Find the nearest size you want to do it properly. Its not worth taking the risk.

Another thing you can do is go to Silverwater if your in sydney and talk to the guys at DBA as they got spec sheets that is not written on the catalogue that spare parts shop.

I wouldn't risk modifying DBA's discs now they source many of their range from TW. Myself and others have done the same mods over the last 10 years on MANY corolla's with a lot of those seeing track work (using custom DS2500 pads, cut down from an evo pad or SW20 turbo Greenstuff pads) with zero issues. Most were doing using brembo discs or the old Aus made DBA's, quite a few with genuine toyota discs too when they were in good condition (AE101 superstrut discs, 275x25mm). The majority of the disc modifications were done by Kevin at St Mary's Specialised Brake and Clutch after consulting DBA directly. My Mrs's daily driver still has the same style upgrade with turned-down brembo 5x100 discs redrilled to 4x100, they've clocked up 40,000km now with zero issues and were engineered in Sydney and are also now modplated in Brisbane. The engineers saw no issue with the structural integrity of the modified discs.

Thats good to know you got no issues with it. Possibly there are some disc that are defective in metal structure and sadly I witnessed the unfortunate ones.

Good luck with your mods.

Cheers

[the_random_hero]

So you've just decided to go for a thicker rotor instead of bigger diameter? If they bolt up, then this probably means I can fit ZZE123 calipers AND rotors onto my AW11 (assuming ST205 has the same mounting holes as ST202 calipers).

[CHA54]

55mm center bore on the ST202 disc. Not sure what the AW11 is, I'm assuming it would be 54mm like the AE82 and AE92's.

[Rolla Boy]

DBA will drill out blank discs to suit your needs, give them a call rather than re-drilling discs...

[the_random_hero]

55mm center bore on the ST202 disc. Not sure what the AW11 is, I'm assuming it would be 54mm like the AE82 and AE92's.

You are indeed correct, that's taken care of already though. What are ZZE123 calipers like in terms of piston size?

[CHA54]

DBA will only redrill if they've got blanks in stock. If the rotor you're after is one they outsource you're out of luck.

[MR22ZZ]

found out today that ST202 calipers don't fit over my 278mm ST185 rotors... :(

ST202 twin piston calipers now for sale (includes pads with some life left) etc

they would bolt up fine with smaller diameter rotors but since the ZZT-231 calipers I have bolt up fine I didn't bother looking into this any further.

[the_random_hero]

found out today that ST202 calipers don't fit over my 278mm ST185 rotors... :(

ST202 twin piston calipers now for sale (includes pads with some life left) etc

they would bolt up fine with smaller diameter rotors but since the ZZT-231 calipers I have bolt up fine I didn't bother looking into this any further.

So have you tried ZZE123 rotors? ST202 or ST185 calipers with ZZE123 rotors is the route I was planning on going.

[MR22ZZ]

nope, I don't have any ZZE-123 rotors to try on, it may work but it will be a close fit.

[vvti16v]

When I installed my AE101 twin piston on my 1ZZ I had to use the 2ZZ disc and machine them down to fit