996 fitting guide

[4WheelDrifter]

The RS2 hardline idea is a crap one IMHO, they don't even fit corectly as pointed out. I originally made my own hardlines, 400mm of tube with 2 male M10x1.0 fittings IIRC. The next time I had to get the brake disk off I went back to flexi hoses.

[Knight Rider S4]

I bought the RS2 bolts for calipers to,..Jonas the hardlines you used just look like normal copper piping ?..2 male ends ..........then you connected one end to caliper then the other to female end of flexi hose?

[Jonas_R]

That is good to know, I cant edit my post but perhaps an administrator could add the RS2 caliper bolt part no. Also do you have the part no. for the Zimmerman disc?

[Jonas_R]

Well the hole pad is inside the disc, so I dont believe that will be to big of a problem.
I rather want a bit more clearence, just to be one the safe site
Someone suggested using 4mm spacer, I found that to be to much, so I went with the 2.88mm washer instead. But I must say that it seems to fit nicely right know.

[Bram]

Well I used the washer because the the calipers were getting to close to the disk. I dont mean the pins but the caliper itself. Without the washer there was around 1.5mm with the washer around 4mm.
Well the pins are designed for a 28mm disc, I used a 30mm disc. Therefor you should take min. 1 mm of all pins. I took something like 1.5mm off.

OK, I understand what you mean. 4mm is quite a lot, and from my experience 1.5mm is enough room between caliper and disc. You will loose quite some disc surface, when the caliper is further above the discs in your case. When the discs get really hot the discs will expand a bit, but not more then 1mm. Anyway, staying on the safe side is always good

[Bram]

O yes, I also used the RS2 caliper bolts, which fit as well:

4x N 100 650 02 - RS2 caliper bolts without VAT 6,40 Euro

[Jonas_R]

Well I used the washer because the the calipers were getting to close to the disk. I dont mean the pins but the caliper itself. Without the washer there was around 1.5mm with the washer around 4mm.
Well the pins are designed for a 28mm disc, I used a 30mm disc. Therefor you should take min. 1 mm of all pins. I took something like 1.5mm off.

[Bram]

Very good write up! May I ask you why you use the washer? I have mounted several 996 calipers, and none of them are too close to the disc (I also use Zimmermans 323mm and RS2 caliper adapters). What I also did different is that I took off 2mm from all pins instead of 1mm as you suggest. O yes, and I would advice to replace the old rubber S2 brake lines as well and get a nice pair of Goodridge flex brake lines.

Nevertheless very good use of pictures to explain everything!

[Skull]

I would say no, because the outlet on the s2 caliper is all wrong. You have to do some serious bending to get it to work. So I would say no no

yes i understand what you are saying, this calipers has the oil outlet at the side. too bad

[Matt_D]

Excellent thread will come in handy when i find some 996 calipers for mine !

Ahhh look at the lickle cuddly wuddly doggy guarding the brakes

[Jonas_R]

I would say no, because the outlet on the s2 caliper is all wrong. You have to do some serious bending to get it to work. So I would say no no

[Skull]

Can the rs2 hardline be used also with stock S2 brakes?

[Jonas_R]

Hehe yeah they really make the dewalt solid as steel these days

[Alistair C]

Nice photo guide but I'd suggest you get a set of axle stands instead of using a dewalt torch

[Jonas_R]

Well the alloys are actually getting sold, becuase the inside of the rim and the caliper is to close. I decided to get my old RH ZW5 rims refurbed instead. They have much better clearence.