GETTING THE BIG BRAKE

How To Add Supra TT Rotors And 300ZX TT Calipers On A 240SX

This is what the stock Nissan 240SX package looks like from the factory.

It’s springtime and around here activity is definitely flourishing, as guys prep for all the events they plan to attend. Just about everybody is upgrading their cars for the season, adding a few new parts to really make an impact. This month we bring you an upgrade to Underground Motorsports’ demo 240SX. Stillen big brakes are hot items and we are psyched to present this install.

Before this project even began, the Underground crew had been debating whether to fit the RB26DETT-powered ’98 five-lug 240SX with a JDM brake kit, such as Rotora or Endless. The other option was to go with the tried and tested 300ZX brake swap. To make it more interesting for this install, Underground hooked up with Stillen and Mckinney Motorsports so that HCI could give you an in-depth look at how to install the Supra/300ZX brake upgrade on a 240SX.

With the wheels removed, you get a much better look at the stock braking setup.

Notice how small the factory caliper and rotors are compared to the new braking package.

From this point, take a look at the back of the two-piece caliper and you will see two screws that bolt it together. Remove them and pull the caliper apart using a 19mm socket. (Do not discard the screws because they will be used at a later time.)

You can now remove the stock brake pads.

For those of you who have been driving around with a stock 240SX brake setup, we feel your pain. In the rain, it can be absolutely horrid and at high speeds it feels like it takes the car forever to stop. From there, the situation just worsens. If you are fortunate enough to have swapped out your stock setup for the Z32 300ZX brake upgrade, congrats! Your car not only looks better, but your braking has been improved immensely. This brake upgrade is worth every penny and it’s one that we always recommend to 240SX owners doing swaps or who simply want to go fast.

The top part of the caliper that was just removed attaches to the brake line. Carefully disconnect the brake line from the chassis. (Be prepared for fluid loss—have a towel and oil pan ready.)

With the top of the calipers completely removed, it’s time to remove the bottom. There are two screws that hold it in place. Once you have removed the two screws, the bottom of the caliper will come right off.

Now you should be able to pull the rotor right off the car with no problem.

t is now time to pull out the Underground/ Mckinney Motorsports conversion bracket. The bracket acts as a spacer allowing the 300ZX calipers to clear the Supra rotors. Attach the bracket using the two screws previously removed from the 240SX caliper. Once this has been fastened, it is time to attach the new 300ZX calipers.

If you diehard Nissan owners are ready, then keep on reading, as this install will definitely be worth your while. The Supra TT rotors from the ’93-’98 Supra are 324 mm in diameter, 44mm larger than the 300ZX rotors. That amounts to a respectable 15-percent gain in performance. When going with an RB-powered 240SX, you need all the braking power you can get. But you should note that when doing this brake swap, you will need to go with a minimum wheel setup of 17-inches (or larger). Anything under 17-inches in diameter will not clear the rotors and calipers. The 5Zigen FN01R-C were the wheels of choice for this particular install, but any good wheel manufacturer will have a setup that you can use.

The 300ZX calipers need to be grinded down about 2 mm using a Dremel tool. This is very simple and should only take a few minutes with the proper Dremel bit.

For those readers who are more about show than go, you can also respect this kit installation. By using a 17-inch wheel, you will barely be able to fit two fingers in between the rotor and wheel, so you will fill up the wheel centers. Stillen offers a wicked set of cross-drilled/slotted rotors, which we used here. As you can tell from the photos, these things look killer!
The brake swap that was done on the Underground/Mckinney 240SX took roughly 30 minutes per wheel to complete. As we go through the swap, pay very close attention to the detail put into the custom brackets. Stillen spared no expense on the creation of its custom parts and we think it provided some of the best-made components we’ve seen—especially for the price. And stay tuned for an upcoming issue of HCI, as we will be working with Underground on the suspension and wheel/tire combo for its 240SX.

Parts Used:
Stillen Slotted/Cross-Drilled (PN TOY2200XS)
Supra 324x30mm Rotors
Stillen Metal Matrix Brake Pads (PN D1170M)
Nissan OEM ’92.5-’96 (All Models)
300ZX Iron Calipers
Nissan OEM Shim Kit and Brake Kit (PN 41080-40P27)
PDM Racing 240SX-to-300ZX
Conversion Brake Lines
Underground/Mckinney Motorsports
Conversion Bracket
(available only with full conversion kit)

Tools needed:
Socket Set (including 32mm)
Combination Wrenches (box wrench)
Dremel Tool (to grind down the 300ZX calipers)
Towel and Oil Pan