Updates

Measured up the rotors properly on a granite slab. I was pretty close with calipers actually (withing .004").





I've been working with Stasis on the issue and they've been super helpful and I think we've found the problem. Will update further soon.

Bilstein really came through so it looks like that's going to be all sorted out by next week too!

Alcon/Bilstein Update

Got some specs from Stasis on their hat's and brackets. I was able to measure everything on my end and found that their hats are off by .132" which accounts for almost all of the misalignment. A thinner washer in between the hat and rotor would remove the other .018". Waiting to hear back from them on that.. The spacer still may be the solution but a proper hat would be nice.

Spoke with Bilstein about the AK-1020 insert and looks like they have a 1" internal spacer. They can shorten the shock body 2.5" and the shock rod by 1.5" leaving me with a ~2.75"/3" split at the lower ride height. They may even have a set of coilover housings to finish things off. I'll know more tomorrow hopefully.

Alcon fun..

Here you can see the calipers is offset outboard too far..



Stasis bracket



.340" of clearance from the rotor to pad guide pin



.040" of clearance from the rotor to pad guide pin




370mm Alcon Rotors with Stasis hats



At this point I think my best option is longer wheel studs and a .150" spacer behind the rotor to center things..

Bilstein Debacle..

Purchased the shocks from AllWheelsDriven since they are the local Bilstein dealer. They specialize in rally stuff and that seems to have created some issues. Below you can see the AWD strut tube with my laser cut brackets tacked on and Vorshlag camber plates/upper perches. Looks nice but it's about 2" too long and the insert spec'd by AWD is wrong for my application as well. It's an AK-1020 insert which has 7" of travel but the shock housing is just too long so it eats up all the bump travel just getting to ride height..

I'd like to lower the car 1" from stock but that puts it at ~.875" of bump travel and ~5.500" of droop travel. Not so good... Even at stock height it has 50% of OEM bump travel. These would be perfect for a rally car that was lifted 2"..



Close up of tacks.. The ears are mounted as high as possible to maximize bump travel.



Rear upper mount I designed. I spec'd the rear shocks which actually work very well for this application. The OEM setup is eye to pin whereas this is an eye to eye shock. That's why I made the new upper mount. I end up with more travel than stock and only lose .500" of bump once it's lowered.







The shock is also inverted to reduce unsprung weight

Basic Setup

Only mods at this point are the tires and wheels.



17x9 Work Emotions with 255/35/17 Toyo 888Rs.