Brake Porn III - the revenge

[s2avant]

As some of you know I am a bit of a brakeophile and have a very expensive habit of upgrading my brakes whenever I need new pads/discs (or when I get bored). Since buying the car all those years ago it has now had six brake upgrades (3 front, 3 rear)

1. I started off with the old favourite of RS2 front calipers with 314mm A8 discs. Not bad especially compared to the stock setup.

2. When it was due new front pads I then stepped up to the RS2 'big red' setup again with A8 discs(323mm this time). Better than before but still room for improvement.

3. Meanwhile at the back I upgraded to 256mm TT discs with B5 S4 calipers.

4. The RS2 'big reds' fell victim to the familiar corrosion issues and got to be so noisy I just had to upgrade to the RS6 365mm setup. No really, I had to

5. It was the rears turn to be played with again after that with the now familiar 300mm B7 S4 setup.

This gave a very well balanced braking setup which has since been used by quite a few people to good effect.

Now the reason for me mumbling on is that as the 300mm setup was becoming common and I was getting a bit bored with it so my mind started to wander. About six months of discussion and design with Jason 'the wizard' Dakin culminated in upgrade number 6...

[s2avant]

This time it is the 2009 S6 V10 that offers up it's parts. The s6 has a 330x22mm setup but uses an electro mechanical parking brake so the caliper is no use. This isn't a problem as the B7 S4 caliper is a perfect fit in the S6 carrier. They even use the same pad dimensions.

Old and new side by side:


Carrier comparison:


Now the astute amongst you will notice there is a different wheel spacer shown with the new parts. This is because we came across a problem with the 330mm disc. The hat height is out but about 10mm. This meant the disc was too far in and the caliper couldn't be fitted. After much head scratching an elegant solution came to mind. We needed to move the disc out by 10mm which is exactly the same as the thickness of the spacers used on the S8 wheels.

So why not put the spacer behind the disc? Well it could be done but the spigot on the rear hub would be in the way. Unless of course you machine the hub and had a custom spacer made. Thankfully Dave (Carly's dad) once again came through with the goods.

Machined hub:


Custom spacer:


With the new hib and spacer in place it is an exact replica of the existing spigot so disc and wheel fitment are unaffected. By placing the spacer behind the disc I am fixing my rear wheel offset at 45mm but this isn't an issue as both my road wheels (S8) and track wheels (A8 sport) are 45mm offset.

The only other problem to overcome was the fixing holes for the S6 carriers are M12 wheras the S2 has M10 holes in the rear uprights. We did plan to remove and machine the uprights to the M12 size but instead we have helicoiled the carrier.



[rant]At this point, I've no doubt someone will come along and tell me how my car is danger to other road users and that I am the scum of the earth for even considering driving it with a helicoil (not to mention my woefully inadequate standard master cylinder) [/rant]

After this it was plain sailing as everything bolted into place. The handbrake cables needed to be tweaked again but they still fit fine.



And finally the obligatory wheel shot:


Ben

[Acidburn]

Nice upgrade there ben, how have you found the balance? and would this be able to be transferred over to the coupe?

suppose the handbrake cable would be the main pita.

[s2avant]

The balance is just about perfect.

No reason it wouldn't fit the coupe. You need 18" wheel though to fit the calipers in as the handbrake springs stick out quite a way.

Ben

[NEO]

Thanks for the thread man! =) I feel the same as you do over brakes. There's something erotic about big brakes.

But now my 324x22 feels a tad small. Hehehe...

I must ask you man... Since you bought new carriers, did you not buy the RS6 carriers for a reason? Since they have M10.1.25? Just wonder if you checked them out and came to the conclusion that they wouldn't fit?

I would like more detail on the helicoil procedure! As detailed as possible. =) Where the parts were bought and what drill size that was used and so.

Thanks again for this thread man. =)

[s2avant]

Sadly, gone are the days of me being able to order anything I like just to try it. Nowadays I have to buy things. We went with the C6 S6 setup as it was the one I found and liked the look off, no one else was playing with '09 S6 stuff so I wanted to be first. It is also relatively cheap (carriers were £60ish a side, discs are £45ish each) compared to C5 RS6.

Ben

[M_GORDON]

Ben

How I can put the Spring on it?
In other foros I see some people mount this spring on his calipers for return the handbrake piece

[Rusty]

you're officially mad! Your rears are bigger than my fronts now! Good work playing with the new toys tho, I'm sure there's lots of other little projects you've got on the go that we'll find out about soon enough.

[NEO]

Like the R8 V10 cheramic brakes.

you're officially mad! Your rears are bigger than my fronts now! Good work playing with the new toys tho, I'm sure there's lots of other little projects you've got on the go that we'll find out about soon enough.

[NEO]

The balance is just about perfect.

No reason it wouldn't fit the coupe. You need 18" wheel though to fit the calipers in as the handbrake springs stick out quite a way.

Ben

Do you know if the helicoil goes from M12x1.5 to M10x1.25 or if you convert it to M10x1.5? I'm currently looking at a timesert solution. http://www.timesert.com/

[s2avant]

Neo,

I will ask Jason (UR-S4). He does all the work for me. He is away but should be back around Monday.

Ceramic brakes need 19" wheels and I don't want to go bigger than 18"s. The next tweaks will be in progress soon though.

Ben

[NEO]

Neo,

I will ask Jason (UR-S4). He does all the work for me. He is away but should be back around Monday.

Ceramic brakes need 19" wheels and I don't want to go bigger than 18"s. The next tweaks will be in progress soon though.

Ben

Sweet man!

Are those the S4-b7 splash shields you use? did they fit without a fuzz? You have any pictures on just those on the car? without any brake disk infront? I bought the RS4 B7 ones but will need to modify them massively to make them fit. Same modificaion as I have to make in the front for the Phaeton splash shields (with air scoops).

[Acidburn]

The balance is just about perfect.

No reason it wouldn't fit the coupe. You need 18" wheel though to fit the calipers in as the handbrake springs stick out quite a way.

Ben

Thats a bonus then that i've got 19's on mine, think I might attempt these then

[s2_bo]

Great chrimbo presie to yourself man!! I like it!!

[s2avant]

Sweet man!

Are those the S4-b7 splash shields you use? did they fit without a fuzz? You have any pictures on just those on the car? without any brake disk infront? I bought the RS4 B7 ones but will need to modify them massively to make them fit. Same modificaion as I have to make in the front for the Phaeton splash shields (with air scoops).

The back plates are B5 RS4. We did try the B7 S4 but they just weren't suitable. As you have found with the B7 RS4 ones they would need massive modification.

There should be some pics in HERE. I can't see they pics at the moment because I'm at work though so I'm going from memory.

I haven't done the phaeton fronts yet. Have you got any pictures/details on the fitment of those?

Ben