RE: | HELP | G60 caliper bolton to 4ksq

["Kaklikian, Gary" <Gary.Kaklikian@Compaq.com>]

Yes, RevSport did convert my 4ktq front brakes to G60's using custom
brackets on the oem 4k struts. We're using the 5ktq rotors (ATE Powerdisk
variety) redrilled for the 4-bolt pattern. In retrospect, we probably should
have converted to the 5-bolt pattern at that time. As my car was their
prototype (as it has been for many other modifications), the next conversion
should be routine. Don't know if he (Dave @RevSport) has any brackets for
sale.

Initially, I thought these brakes were fantastic, and they were more than
adequate on the street. Then the car developed a mushy brake pedal, which
stainless steel lines and repeated bleedings didn't cure. On the track, much
heavier cars (S4's) with the G60's were outbraking me, most likely because I
had little confidence in the brakes in that situation.  I don't really think
the problem was pad/caliper fade, but rather the hydraulic system. We
finally decided to scrap the whole oem master cylinder/proportioning
valve/vacuum booster and install a Girling dual master cylinder unit.
Hopefully, I'll have a chance to test this setup tomorrow. 

I'd be interested to here from others who have converted to G60's to see if
they experienced similar problems, or if they swapped the master cylinder
and/or proportioning valve.

Gary Kaklikian
86 4kcstq
86 5kcstq

-----Original Message-----
From: Bruce Bell [mailto:bbell04@ibm.net]
Sent: Wednesday, August 11, 1999 9:14 PM
To: auditude@neta.com; quattro-digest@audifans.com
Cc: renneie@hlthsrc.com; Paul_Royal@idx.com; nugen@pwshift.com;
mbenno@minn.net
Subject: RE: | HELP | G60 caliper bolton to 4ksq



>  had an email that I saved long
> ago from someone,
...snip..
> (If you remember the email/post I'm referring to, it
> starts out by saying "Okay, I could have sworn I've posted this
> before...")

That post was from Ben Howell. I'm not sure if he is on the list anymore
(I've been unsuccessful at reaching him lately) so I'll take the liberty of
reposting it with my own comments. Read carefully!!!

>   I could have sworn that I posted this before, but I will
> again..........
> Yes, it CAN be done and pretty simply and with parts from
> your local junk
> yard.
>
> A) the G60's will NOT bolt onto the 4k strut without a custom braket.
>
> B) Get the following parts: A pair of G60 calipers (the dual piston
> calipers that appeared on 5ktq, 200Q's etc....), get a pair of strut
> housing from a 1988 or 1989 80/90 (quattro or not, it doesn't really
> matter), get a pair of rotors from a 1990 or 1991 20v 90Q
> (part # 893 615
> 301A dealer list @ $155.60....also available from KVR in
> cross drilled form
> for $100/each KVR part # AU-250) NOTE: DO NOT get the rotors from a
> 1989-1991 CQ, they are the right size and bolt patteren, but
> they will NOT
> work. Also get some barke pads while you are at it. :) (personally, I
> recommend Ferodo's for street use)
>
> C) Swap the wheels bearing and hub (now is a good time to do new wheel
> bearings) from your 4k into your newly aquired 80/90 struts.
> also swap your
> springs and strut inserts onto the 80/90 housings.

Ooops, here is a MAJOR problem. The struts from an Audi 80/90 have 75mm OD
bearings and the struts for the 4kq use 68 OD mm bearings (ID are approx. 42
and 39 mm respectively). This means your 4kq hubs won't work. This also
means the 80/90 hubs won't work because not only are the axel spines
different, but the 80/90 uses a bolt rather than a nut on the axel.  Now if
you are very clever you might realize the rear bearings on a 4kq are 75 mm
and you might think you could use a set of those up front....Wrong. The
front and rear axels on a 4kq are different and also have different splines.
You can go a couple of steps further and solve this problem. Get the front
hubs, 4 of them, from a 5000 t or tq and an extra set of 4kq rear axles
(they need to be shortened slightly with these struts) and convert to a 5
bolt system. you can then use the front rotors from the same car you got the
G60's (even the hat size is correct) and drill you rear rotors to work with
5 bolts.

Or, you could fabricate brackets.... or talk to Gary Kaklikian,
<Gary.Kaklikian@Compaq.com> RevSport converted his car to the G60.

> D) Bolt it all to your 4kcsq! :)
>
> NOTE #2: I do not recommend that you get strut housings form
> a later 80 or
> 90 (90, 91 or 92). They used the "cast" style a-arms and had
> completely
> different set-ups for the sway bar. If you do get that strut
> housing, you
> will need the entire front suspention (except the sub-frame).
> I have never
> used this style suspention, so I can not add any more details
> than that.
>
> Hope that helps! BTW, the G60's on the smaller cars is down
> right awsome!
>
>
> Laters, Ben