Boosted Falcon

As most of you are aware I've been toiling away trying to get some kind of brake/suspension upgrade for E-series cars, via fitting AU uprights but without the pain of fitting an AU K-frame.

I've made a hybrid arm consisting of a modified ED LCA with an AU ball joint end on it, then paid 11tybillion to have that design turned into a CAD file, and now I'm paying another 11tybillion to have a single set made so I can test them and check I have the angles correct (Camber, caster, toe, ackerman, making sure the ball joint is in the middle of its travel at normal ride height, maintaining the original ride height etc).

So the idea is, buy these lower control arms, stock AU uprights, stock AU upper control arms, then whatever brakes you want (Stock AU, drilled, Brembo, 356mm 8 piston, whatever) and bolt it in.

If I've done it right you'll have correct AU offset and the ability to fit any brakes that fit AU-BF and probably FG, along with more caster and unchanged ride height from when you had original e-series stuff.

At this point they're only to suit EA-ED, EF/EL have a different inner bush and I haven't looked into what's involved in making them fit, if I get enough interest then I'll get some made.

Unfortunately they're going to be a bit exxy as they require a 5 axis mill, unless I get this test set made and figure out how they can be changed to only require a 4 axis mill.

At this very very early stage it looks like they'll be anywhere from 1200-1500 for a pair if I get a batch of 6, made of T6061 alloy. Less if I can work out a way to make them simpler again or we get more people interested.

So, if the idea grabs you start putting some money away each week until I have a test set and pics and a better idea of how much it will cost.

I've put more than 2k into this already so I'm really really really really really hoping I've got it right...

Props to you for doing this, I hope it works, i'd probably be down for a set for the next project.

As you know I'm bloody keen on this. I'm definantly down for the group buy
Better start putting some cash away

just get a grinder a block of billet, win!

but yeah, well done for getting your shit together, will be good to see the results.
im sure if you can prove they work you will have a big market through workshops.

id buy em. nice work mate.

i just have to get a clutch first for the t56. which should be very soon.

I'd be keen. Except I have an EF. Damn. So I'll continue waiting!

I have an EL k frame in my car. Would it be easier to rebush the arms to suit or change k frame back to ea-ed?? How different are the bushes??

Someone get me pics of an EF K-frame and pics of an EF lower control arm, maybe it'll be easier than I think it will...but probably not

Are EA-ED and EF-EL k frames interchangable?

Yes.
aslong as you swap the gear that attaches to it.

i have seen the replacement arms that repco, burson, etc supply for EF EL and they look like a EA - ED bush with a spacer infront to make up the loss of the original bush.

These comments are useless without PICS!

If I can get a spacer made to make these arms fit EF/EL then we're sweet

interested in EF but the co$t is rather steep for me

Start saving then. He doesn't want your money tomorrow

cant justify that ammount.... $1200 + cost of uprights and anything that need replaced on them + cost of brake setup = scary on apprentice wages plus i'm already saving to get Paul to tune the shitbox

I got AU discs, twin piston callipers, uprights and upper control arms for $40 from the wreckers.....the only other alternative is the ebay brake kit which does come with slotted rotors but it's a homo offset, you've got a good chance of getting the wrong or miss-matching uprights and it's $1700.

I know over a grand for some sticks of metal is a lot of money, believe me when I tell you I'm trying to keep the cost down! But unfortunately it's pretty much the only option unless you want to put in an entire AU K-frame or run the ebay kit...

Start saving!

Very keen on this, the cost might be a bit to scare me off, but, i would love a set for the future! (I want Au spec offset front, and rear in the future )

I know of 3 people including me from WA who will put money up if they work.

Mmm id love to see how this goes for sure . Maybe a worthwhile update for the ea

to those concerned about the cost....the only other way to do the same conversion is by fitting an AU k frame to your car...if you didnt have the skills it would cost around the same if not more to have someone fit the k frame up with what mods need to be done..... makes it seem not so exxy in my eyes

no problems, next time i visit him i'll take happy snaps for you

And for all those people thinking that fitting the AU K-frame isn't that hard, take it from someone who has changed there K-frame, it's a ****. If i had the choice between swapping or bolting, i'd pick bolting everytime.

Depending on when this group buy happens, I'll be in.

People don't realize aswell, that once you have this Lower control arm setup, you can get a 6 spot brembo kit and bolt it straight on (providing your running 19s hahha)

BBQBurner wrote:And for all those people thinking that fitting the AU K-frame isn't that hard, take it from someone who has changed there K-frame, it's a ****. If i had the choice between swapping or bolting, i'd pick bolting everytime.

Yes!! 90% of the people on this site could swap a set of control arms - not any harder than doing springs really - but only maybe <10% could do an AU k-frame swap, and even less people would bother going to the trouble.

Plus you still end up with an enormous steel AU lower control arm anyway...these are going to be billet alloy

What Brembo kits are available for AUs and how much do they cost these days? New or second-hand?

I'd buy these if I didn't have to cough up a couple more grand to get these arms done:

http://cgi.ebay.com.au/Ford-Brembro-BA- ... ccessories

Or there is heaps of stuff on ebay:

http://cgi.ebay.com.au/TICKFORD-AU2-TWI ... ccessories

http://cgi.ebay.com.au/BREMBO-FPV-FRONT ... ccessories

http://cgi.ebay.com.au/TERRITORY-FPV-32 ... ccessories

http://cgi.ebay.com.au/Ford-BF-XR6-Turb ... ccessories

http://cgi.ebay.com.au/BF-FG-PREMIUM-RO ... ccessories

http://cgi.ebay.com.au/BRAKE-PADS-FORD- ... ccessories

http://cgi.ebay.com.au/BA-BF-Front-Disc ... ccessories

http://cgi.ebay.com.au/FG-6Pot-Front-Br ... ccessories

I'm interested to find out if the calliper offset and stud spacing is close to any imports - has anyone ever heard of skyline or supra etc brakes being used on a falcon?

I'm going to try and use these:

http://cgi.ebay.com.au/K-Sport-356mm-8- ... arParts_SM

I think the only issue will be the caliper mounting bracket.

This should allow for a good range of coil overs etc aswell eh...

Well done for persisting with this project!

Negative - I've designed it to keep the E-series spring/shock combo (AU is basically the same but longer) and I've tried to make it retain the original height, so if your car is stock it will stay stock height, lowered 2" it will stay at that height. It remains to be seen if that is the case in real life though....waiting on a test set.

If someone buys my damn 19s it will help a lot!!

When I finally get a job again, I'll be keen for a set. Nothing worse then E series Brakes.

And Dan, whats your plan for the rear brakes? Standed E series?

I have an AU diff so I can fit any B-series upgrade I believe.

The fronts do 80-90% of the work anyway, so if you get good pads and slotted rotors for the rear you should be ok, if you don't want to put an AU diff in.

would there be any benefit of making vented XF rear discs work?

Rollin wrote:I have an AU diff so I can fit any B-series upgrade I believe.

The fronts do 80-90% of the work anyway, so if you get good pads and slotted rotors for the rear you should be ok, if you don't want to put an AU diff in.

I was thinking that since 80% of the braking force is on the front.

And my other thourght was the brake booster. Will the E series 4L one be ok?

Apparently - The ebay twin piston brake upgrade works with the e-series master. I'll have to find out the diameters of the pistons and figure out if the pedal is likely to be higher, lower or the same.

+1 for EF/EL compatibility. Dan, I still have some EL arms here if you want them. Ill most likely be up your way at Christmas. If you can get them for EF/EL and I buy a wagon Ill probably buy 2 sets.

I will deffinately be in for a set to suit el.

Ben

I can see myself getting these, then using it as an excuse for AU IRS rear

I might get a set actually. What is the ETA on the CNC prototypes?

No idea unfortunately, I'm waiting to hear back from them, and once I do I need to give them money which I currently don't have.

Someone buy the 19s I have for sale!

i'm so in for a ef/el set. i've told you a million times.

Just letting you guys know this is still happening. I got a few screen shots of the design they are working with at the moment so it shouldn't be too long before they can make a set.

Still need someone to buy my 19s!!!