Project 450 - Will it be enough!

[Jonas_R]

Brake Porn

Just fitted one of mine 996 calipers today.

Warning brake porn!

RS2 bracket:


RS2 hardline, the org. hardline was a real pita to get off.


Comparison S2 disc to the left and zimmerman 323x30 disc to the right:


996 Calipers:


The zimmerman disc has been fitted, had to beat the dust cover a bit:


Trial fit with the caliper and disc


Very thight fit between the disc and the caliper. Think I have to remove the pads and grind something off.


Caliper, disc and my 17" rim - actually the caliper is rather close to the rim.


Money shot

[CliveH]

Very nice job Jonas, and a great write-up

I'll be doing this bit soon...

[Jonas_R]

Thanks Clive.

I will post the part with prices and part no. tomorrow.
However I think the whole setup is running very close to the inside of my 17" rim. So I think I will have to do some measuring sunday. Iam also afriad that the pins and springs that holds the pads in place are to close to the disc.

[CliveH]

Maybe some 5 or 10mm spacers?

[kwlw]

Thanks Clive.

I will post the part with prices and part no. tomorrow.
However I think the whole setup is running very close to the inside of my 17" rim. So I think I will have to do some measuring sunday. Iam also afriad that the pins and springs that holds the pads in place are to close to the disc.

Measure what is between pad plate and disk (with eyes ), if it's less than 2-3mm, then you may need to take a bit of steel with angle grinder. I did that on mine. Because after heavy use, pad metal plate (with anti squeak weights) started to rub wheel which expanded also due to temperatures from the brakes. Very annoying.

And regarding tight pads - it's better to take some material off (with sand paper "brick" on the plain surface for example), because when you will heat up whole stuff, the disk will expand, pad metal plate will expand, and you MAY notice undesireable effects. One MM from each pad is enough IMHO.

Sau

[Jonas_R]

Thanks for the advice Sau Will do some measuring then.

[Jonas_R]

Did some measuring today, and I decided to use my old RH ZW5 rims instead. They clear the caliper with 8mm, which be more than enough.

Guess I will have to sell my Rial Nogaro rims instead. More pictures next week when I mount the other caliper.

[Jonas_R]

Just shipped my old RH-ZW5 rims to Felgen-Garage in Germany for restoration.
Should have them back start of march, looking forward to that.

[Jonas_R]

Couple of updates

Lots of good news:

Got an email today from Felgen-Garage.de and my RH ZW5 rims are going to be done next week and shipped back to me. I should get some pictures next and I will post them.

Got the car out of the garage today, first time for a couple of months since it has been in winter hibernation. Did some test runs with the new brakes and everything works like a charm. The car feels totally different now when braking.

Also bought a wideband sensor kit from Zeitronix, this should be a nice add on so that I can monitor the AFR.

[Jonas_R]

Ohh yeah I also made a fitting guide for the 996 calipers.

It can be found here

[javispa]

Very nice thread Jonas.
I am planing to do something like you in half a year more or less. I already have the RS2 turbo, the exhaust manifold and the Samco hoses. I also have the 996 calipers mounted, but I will have to check the mounting, as I think I have not removed the 1mm from the caliper pins and it makes some noise when not braking.
I wanted to ask you a couple of things... did you get the replica injectors from 034motorsport? And about the mapping... I imagine that you changed the map sensor for a 300kpa one, and who does your mapping?
I hope to see the project finished and getting good power levels at high rpms.
Cheers, Javier.

[Jonas_R]

Very nice thread Jonas.
I am planing to do something like you in half a year more or less. I already have the RS2 turbo, the exhaust manifold and the Samco hoses. I also have the 996 calipers mounted, but I will have to check the mounting, as I think I have not removed the 1mm from the caliper pins and it makes some noise when not braking.
I wanted to ask you a couple of things... did you get the replica injectors from 034motorsport? And about the mapping... I imagine that you changed the map sensor for a 300kpa one, and who does your mapping?
I hope to see the project finished and getting good power levels at high rpms.
Cheers, Javier.

Yeah I got the replica injectors from 034motorsport, but I ended up selling them and using oem RS2 injectors instead.

For the map-sensor I used a Vmap-D mapsensor, that works as the RS2 bosch 300kpa mapsensor.

A company in Denmark did my mapping, but it does not work properly. So Iam in the progress of fixing that.

[Jonas_R]

RH ZW5 back from Felgen Garage.de

Just recieved my RH ZW5 rims after they where refurbed by felgen garage.de

Must say they look really nice, I cant wait to get them on

Getting tyres on them tomorrow and then I will fit them there.

Here are a couple of pictures:

[Jonas_R]

Update - EGT, Wideband and Boost installed

Some more updates.

Managed to install my tripod gauge holder from Gerd.
And at the same time I hooked up my wideband sensor from Zeitronix + my VDO boost gauge and my VDO egt gauge.

Now Iam just considering if I should try to splice into the boost signal from the mapsensor, so I could log this aswell and perhaps also splice into the EGT sensor.

Should I splice into the other sensors?

Also should I paint the Wideband sensor gauge black? or get chrome rings for the VDO gauges. On the last picture the VDO gauge to the left has a chrome ring on.

Pictures:

[MattS2]

Jonas,
I'm interested in the sportscat you fitted. Where from? and How much?
How did it affect the car after you fitted it?

Also, Why did you not use the 034 replica injectors?

Cheers
Matt.