I typed a nice long paragraph and lost it to crappy 'net.. :-\
Anyway, just to clarify:
4wd EA car with ER/XT6 rear hub unaltered
EJ backing plate, handbrake setup, rotor and caliper.
Rguyver used an r180 setup on his brat, for those that don't know the r180 STI setup has bigger diff, axles and hubs thus the backing plate centering hole is bigger than r160. The r180 hole is bigger than the bolt pattern for EA/ER hubs thus rguyver simply welded a ring inside the r180 backing plate with the ea pattern drilled into it and bolted the assembly up.
R160 backing plate center hole is a hair over 10mm larger in diameter than the ea/er mounting hole, thus the ea holes have to be drilled into the ej r160 backing plate.
Th ej backing plate fits flush to the EA hub/trailing arm, there is no spacer between them. What I have done is simply made a ring with ea inner diameter and ejr160 outer diameter that makes up the difference in diameter as well as a plate that sits outside the ej backing plate.
These are the full dimensions of what I fabricated minus one alteration I did when I actually went to put averything together and forgot that I needed to make room for the movement of the lever that controls the handbrake shoes:
There were a few things I wanted to acheive:
Reversibilty: If at some point I ever dump my car and went ej any alteration I did to the r160 backing plate couldn't prevent it from being returned to an ej car
Safety: Must be as safe as stock
No welding
Must be able to fabricate with simple electrical/hand tools (...who was I foolin'?)
No unblocked holes in the ej backing plate: This explains the unusual shape of the adaptor plate
Must be compatible with an ABS backing plate, crossbred kit is NOT (no you still can't mount and ej abs sensor)
and finally Must be freely availible to all who are as insane as I am:lol:
The prototype is made of 6mm aluminium. I will update here with the actual method and more pics (Please, Sis, can I borrow your camera again?) as well as complete DXF files and DWG for those that desire to do the smart thing and take the damn design to their nearest cnc water/laser/3 axis machine and have it do in seconds what I did with my hands a jig saw a drill press and a bench grinder..
damn anyone actually gonna read all that?
Kaz