Cusco brake cylinder stopper

[tangcla]

I fitted mine today.
I opted for the brake stopper to be separate from the strut brace, as I was told that this configuration has more flex reduction, at a higher cost and also more installation hassles.

The Cusco brake stopper has three bolts that need to be attached; all of which are in very awkward positions, especially the rear one, which needs a nut to be tightened from the wheel arch. This is very hard to do with the wheel on - which is what we did and I'm sure if we jacked the car up and took the wheel off, everything would have just been so much easier. But that's what happens when you try to cut corners

I'm impressed with the brake feel though. For ~$100 it gives great response, the pedal feel is so much more precise, even on light braking.

[vratenza]

hi Tangcla! Need your help. I just bought the Cusco Brake stopper as well and was figuring out how to fit it. I understand that there are 3 bolts to hold the structure in place.....

I've identified 2 of the original bolts that goes into the holes but the third is elusive. The closest i can find is the depression (circled in red) in the picture. I have not really tried to install it but do i need to drill a hole through that depression? Thanks!

[tangcla]

It should be the hole which is just obscured by the metal bracket. You have to screw it through the wheel well.

[PHAT GT]

hi Tangcla! Need your help. I just bought the Cusco Brake stopper as well and was figuring out how to fit it. I understand that there are 3 bolts to hold the structure in place.....

I've identified 2 of the original bolts that goes into the holes but the third is elusive. The closest i can find is the depression (circled in red) in the picture. I have not really tried to install it but do i need to drill a hole through that depression? Thanks!

just push on the section circled in red with a screw driver and it should just pop out and you'll have your third hole

Michael

[vratenza]

Thanks guys! One or two more dumb questions and I am all set.

The japanese instruction sheet is of little help..... but I managed to figure that the different bolts goes into the following holes A, B and C.
With bolt A being the longest and biggest (12mm head?)
Bolt B the middle length (10mm head?)
Bolt C the shortest (10mm head?)

Where should the "C" and "O" washer go?

[tangcla]

ahh yes, that's right! Michael's right about the third hole, my bad.

I think the third hole is the 12mm, and the other two are 10mm. If i recall correctly, the vertical one should be the longer bolt, and the horizontal two bolts are the short 10mm and the 12mm?


hmm, these pics don't really help... but here you go

[vratenza]

your picture has been a great help!
From the pictures, I think the "O" washer goes to A and "C" washer goes to C.

But I do think the larger head bolt (12mm)which is also the the longest is at A as you can see from the material of the bolt in the picture.

[teK--]

Thank God for this thread!

Mine arrived yesterday the Japanese instructions are hard to follow and the pictures blurry. With mine I did receive two very thick washers about 3-4mm thick and the same size as the "O" washer in the above photo. In the printed instructions it shows to put one of them on the "A" bolt (in above photo), inbetween the BCS and the car.

No idea where the second very thick "O" washer is meant to go though. I'm sure once I go to fit it, it will become clear if something doesn't line up or if there is a gap.

The largest of the three bolts definitely goes onto the "A" location, I confirmed this by comparing the japanese characters printed in the parts list and on some of the instruction photos.

[smythie]

Just to clear things up

"O" washer = plain washer
"C" washer = spring washer

[teK--]

Since I am getting quite a few PMs about where to buy one, here is where I bought mine from:

Japanparts.com, part #376-311-009

It is about $120.00 landed (mine was a little cheaper since I had some loyalty points with them). I'll put some pics up showing what goes where when I install it on the weekend; before I found this thread I could not find anywhere else with directions.

Jim

[teK--]

I fitted mine today and for the 2.5i (perhaps 2.0R too) some minor modifications need to be made. There is a small resonator hanging off the intake pipe which gets in the way of the adjusting bolt on the cusco unit.

Also for some reason in my kit, the adjusting bolt looks to be at least 25% longer than the one in Tangles' photos. Basically when the bolt was fitted, the end of it hits the resonator by a LONG shot. I had to cut 1.5" off the end of the bolt for it to fit under the resonator. A Dremel is perfect for this. Even then the cusco unit itself rests against the resonator and so I stuck a strip of dynamat on the underside of the resonator to protect it from abrasion.

3.0 and 2.0GT, 2.5GT will not have this problem as they do not have this extra resonator box.

Bolt "A" in the above photo is very tricky to tighten. You basically need a 12mm hex-drive socket, then one of those right angle screwdrivers (a racheting one even better). There is no way you can fit a regular spanner or socket wrench in there.

I did not find a use for the two extra thick washers in the kit.

EDIT: The other thing I did at the same time was remove all the factory shims which I had originally transferred onto the new pads. (The front pads have 2 layers of shims!). Instead I have used the spray-on rubberised anti-squeal product. I am advised that removing the shims also improves the pedal feel noticeably.

[PHAT GT]

just snap of the res box and put some round black plastic bung in there (you can fine these at all bunnings ,sold as chair leg ends)

this box is not needed but will create a little more induction noise when removed "WARNED"

CHOP IT OFF!!!!!

[cruisn]

I made my own BCS for my GT.

If you have access to a welder, steel and and have some abilities, theyre pretty easy. (I also had access to a powdercoat system. )

[teK--]

Looks great Mark, you should make up a jig for a 4th Gen BCS then sell them here

[cruisn]

Looks great Mark, you should make up a jig for a 4th Gen BCS then sell them here

Cheers Jim.

I got oodles of requests to make them up for the Gen2 when i did it, but no longer work in the same place with access to all the required goodies.