Suspension Upgrade Journey
Part 2 - Upgrade Front Absorber to TRD
21 March 2003 (Friday)
Before I begin, to all Malaysians. "Malaysia BOLEH".
Today's objective is to install AE86's front struts + brake rotor disc with TRD absorbers into the KE70 :) but lacking AE86's calipers, top mounts, top coil pans and coils. So "Hybrid" the strut assembly between AE86 and KE70. This is how it went ..............................................
The recipe: -
Easy :)
Step 1, remove the KE70's strut and the 1st thing to check was if the knuckle fit the KE70 Arm, Steering (between knuckle and lower arm). Haha NOT fit :( oh shit........ trouble......... 1.5mm larger center to center, they are off by 3mm total edge to edge.
Step 2, while the mechanic is busy fiddling with other items, the KE70 and AE86 caliper's bracket is compared .
NADDDDDDDDDDDDDD, no............. The KE70's caliper cannot be mounted to the AE86 caliper's bracket. This is a sign of long list of bad luck to come, I can feel it :) muah hahahahahahaha
Step 3, but hey, there are too much troubles already, why not just swap the absorber? wait a minute, can they be swapped? removed from the strut body some how?
Yes :) ,a simple turn on the strut top and the TRD shock is revealed........................ and it is
happy like a little boy who got his candy :)
wow, looks like new and according to the model spec: -
TRD TOKICO
48511-AE941
Race Application
Fixed rate
Cartridge (removable from strut body for quick replacement)
Twin-tube gas
Height - max = 488mm, min = 342mm
Compression 236kgf, rebound 112kgf
Reaction Force of Rod = 15.8kg
Spacer TRD #3 required
short stroke (60mm) non adjustable gas.
So can the KE70's front absorber be removed from it's strut body too. Yes Yippy :).
................................. a moment of silence please ............. .............. unfortunately the TRD absorber diameter is bigger and cannot enter the KE70's strut body ........................... a moment of silence again please ........................................................ so back to square one continue with the "Hybrid" project.
Step 4, now have to fit the KE70's coil onto AE86's strut casing, modifying AE86 strut bottom pan by welding an internal coil guide, so that it won't run around on the big pan.
and the finished product :)
Step 5, grind the lower arm so that it can mate with the AE86's knuckle.
so far so good :)
Step 6, the moment of truth .......... quickly install the disc without proper locking it, no caliper as well and install the tire to check if the height can clear the mudguard.
and ..............................taa daa ................................ OK, pass. My god, I nearly cried if the KE70's original 20 years old coil cannot withstand the TRD short stroke absorber's height reduction and the car's weight. I really nearly cried. Thank god it held. It still have a 3 fingers gap between tire to mud-guard :) I didn't look, the mechanic told me it held then I looked. :~~~~ sob sob, I was so moved ........
Step 7, install the disc. Since the AE86's caliper's bracket cannot mount the KE70's caliper, so use the KE70's shield which comes with the KE70's caliper bracket. It is in better condition anyway, hmmmmmm. (sounds like a fox cannot taste the grapes is more like it)
Step 8, install the AE86's disc and spin it ..... taa daa ..........ssssshhhhhh - what's that????
Dam, the disc is in contact with the shield and grinding..... man, this is sure bad luck. OK, nevermind, slam the part where they touch,....... No use, there is solid behind it and cannot be removed.
Step 9, oh nevermind, remove the caliper's mounting / bracking and mate it with the original AE86's shield. Oppsssssss, they are "STUCK" welded on by Toyota factory.........and cannot be removed and still be useable.....
Oh, what am I going to do now ?????????????
Step 10, give up, use back the KE70's discs, but after install it, noticed it is loose. That's because the thread for the nut to lock it in place does not run deep enough. Assume AE86's hub is thicker and do not mount in so deeply.
Oh shit, this is the x x x x x x th problem since started.
Step 11, OK nevermind it all, match the KE70's disc onto the AE86's hub, since AE86's hub (holder) is thicker and was meant / original to the AE86's strut.
However the 4 bolts pattern / positions are different between the KE70's disc to AE86's holder and some modifications (again) is required.
Step 12, try to look for some Alan-key bolt to replace normal bolt because the edge is blocking it from turning or even access by tools. We had to grind the internals to make it work in the end.
Before the above was completed / fully achieved, another technique was used and more successful / easy, which was
But this side is the rim's side therefore the bolt's head needs to be grind flat to clear for the rim to mount in flat-ly.
Step, The End, the "Hybrid" is still considered successful because so many obstacles was overcome. Although cannot use the AE86's ventilated disc, which I so greedy for, but it wouldn't have help much now without brake pads upgrade. I will regret this one day, I'm sure, :~~~~~ sob sob. I want the AE86's ventilated discs :~~~~~~ sob sob
The summary is: -
Step, The Results, too early to conclude it's effectiveness / matching between coil's stiffness to shock's damping, or my driving style, will update later.
But, hhheheeheheh, hehehehehehhe, ehehhehhhehhee you know what I mean :)
Aftermath
Since upgraded the front absorber with a known compression of 236kgf and rebound of 112kgf, therefore the rear absorber is set to maximum 8 in hope their compression and rebound is closly matched, because this car has near 50/50 weight distribution (55% front 45% rear). At this point the compression and rebound at setting 8 is not known.
Ride Feel
Hmmmmmmmmmmmmm, weird, not really that good in handling??? some times have lots of control, some times loose control on a bump. The car warble on certain bump, don't feel anything on certain other bumps. Difficult to understand???
May be the rear is not matching the front correctly, but what is wrong??? will investigate further in the future :)
ACOUSTICS SECTION AUDIO SECTION CAR SECTION
HOME - Technical Website for Acoustics, Audio and Car
Malaysia
Boleh