Turbo 240SX—Brakes

This season we are converting the brake system to a manual brake system. This will give me feel and keep the master cylinder away from the turbo heat.

We ripped out the brake booster and stole the internals.

We machined the internal brake booster pin so that it just fits through the firewall, then we redrilled a new pivot point on the stoke brake pedal to give approximately 10% more mechanical leverage against the master cylinder.

The master cylinder is the stock 7/8 bore. We kept it, since it has enough fluid to operate the current brake system. The only thing that is not known is how much more pedal effort will be needed. I feel that it should work well, given the new pivot point.

We made up a mounting plate (stop sign shape!) that gets mounted to the firewall. This holds the assembly to the firewall and also holds the master cylinder in place as well.

The master cylinder mounted to the plate. You can see that there is lots of clearance from the turbo side, and we will add a head shield as well.

This season, I am going with a divorced wastegate, however most tracks have noise limits.

You can see the mounting point in this picture, of the wastegate that is now studded.

I decided I did not want the wastegate venting right into the atmosphere, so I had to find a small muffler.

Hrm... what to use. Since all the "SR" boys make fun of the KA24E as a truck motor, I thought, "hey, why not use a tractor muffler."

So, I bought an Allison Chalmers tractor muffler and fabricated a flange and pipe for it.

To keep the heat under control, we heat-wrapped the muffler.

The large, custom oil pan we built.

A picture of the underbelly to illustrate how straight the 3" exhaust is.

The turbo installed along with the aluminium heat shield, which extends far below the downpipe and high above the master cylinder.

This should provide a good shield against the intense head during racing.

We heat wrapped all things that could melt.

The master cylinder now bled and the custom manual brake system now operating. There is a good, stiff pedal and good stopping power (at least, from what we could tell in the shop space we had to test it).

The final outcome will only be known at the racetrack.

A new front brake system was installed. Ducts were added to the Bombex bumper where the signals used to be, and 3" high heat ducts have been routed to the front rotors.

The underside of the car showing off the duct tubes, the new, divorced wastegate, the tractor muffler, and the wastegate and turbo manifold.