4000Q 5-bolt Conversion Completed!

[Kaklikian, Gary]

The 5-bolt conversion on my 4000tq is complete, but only after a lot of
expense, headaches and hard work!  If anyone else is considering this
conversion, my advice is -- forget it, unless you want to spend the money
for an UrQ suspension, at least the front.
But, on the other hand, there are a lot of benefits to using the setup I
did. 

In the front, I have a combination of 4000q, 90Q20v, 80Q10v, and UrS4 parts,
with a bit of machining to the hub thrown in for good measure! Hopefully, I
can remember what model each part came from when something needs to be
replaced! 
This setup increases the front wheel bearing diameter from 68mm to 82mm, has
a much beefier outer CV, and increases the front track by ~2". Plus, the
2-piece strut allows for easier maintenance and more negative camber.

Once the front suspension was complete, the next problem was the brakes. My
A8 rotors were no longer centered correctly on my 996 calipers. So, I had to
switch to a S8 rotor with a deeper hat, at 322x32mm vs. the A8's 312x25mm.
All well and good, except the 16" tires and wheels I just bought won't fit
over the brakes now,  so up to 17" it is.

In the rear, the 5ktq hubs worked fine with the original 4000q setup, but
the 4000q rotors had to be redrilled for 5x112, since the hat depth is
different on the 5ktq rotors.
I'm running 25mm wheel spacers in the rear to match the front track increase
and will be using 235/40-17 track tires.  And the fenders have been cut out
all the way around.

I hope the springs can handle the wider track and the alignment settings
work out. How all of this will impact the handling I don't know yet, but I
can only imagine  grip levels will be much higher. Plus,  the taller gearing
should really help, particularly on the track.   

Again, if anyone is considering doing this for street use, DON'T! It's not
worth the trouble simply to use 5-bolt wheels.

Thanks to everyone on the list who offered advice, assistance, and even
criticism! 

Gary Kaklikian
'86 4ktq
'92 S4