Decided!

[daxyz]

Yet another contribution to this long standing thread - here is the advice from my experience of the brake upgrade so far!

My chosen set up was:

996 calipers
A8 323 discs
RS2 carriers
RS2 rigid pipes
pads, sprung clips, rtaining pins etc.
All behind 16" Avus wheels.

This all bolts tohether quite nicely but bottom line is that it doesn't quite fit

With the 162 wheels the clearance between the outside edge of the calipers and insode edge of the wheels is only a couple of mill at most - but this is just about ok. The main trouble is that the 323 disc is just a little too big in that it rubs on the sprung clips AND (when heated up under normal braking) on the inside edge of the caliper body!

Combined with some rubbing on the splash plates this led to all sorts of unpleasant noises after th rebuild.

Neatest solution would be to take 5mm or so off the discs - will stop rubbing on sprung clips and on caliper body. You cant space out the caliper any further and keep the 16" wheels as the caliper bodies would rub on the inside of the alloys.

So - does anyone know of someone in central scotland who can machine 5mm or so off my discs?!?!? Hopef this will clear up the noise issues.

Derek.

[dan_b]

Guys
If I replace my creaky old 968CS calipers and look to retain my RS2 caliper brackets, am I right in thinking the following:

996 Monoblocks
RS2 caliper carriers
323mm A8 disc

Will all just bolt on under my 17" alloys? I'm presuming I'd have to get new pads as the swept area of the 968CS caliper will be smaller than the 996 Monoblock (I'm on 304mm disc at the mo')?

Is this right? Have I assumed correctly that the 996 is a monoblock and so should be less succeptable to the dreaded pad vibrations/ squeal I'm getting now? Plus I should see some added brake performance with a bigger diameter disc? Or do I still need to machine down the disc to accommodate the caliper?

[BRY]

@danb these fit easily under 17" wheels
they can squeak though !

[T2Andy]

This is the same set up as im running dan 996/323
Dan the only probs im having is when the disks get very
hot ,i get scraping noises probably the metal guide pins
or the metal plates behind hub ,no probs under normal
driving im running 17 in OZ wheels any questions let me know.

[dan_b]

I don't like the sound of scraping noises! I'm getting bad enough noises now

[rotoryboy]

metal guide pins
or the metal plates behind hub

You can slide those pins out a mm or so and the metal plates can be replaced with the smaller RS2 ones

[dan_b]

Hang on, are the 996 calipers the same mechanical design as the 968s? I thought they had a different pad retaining mechanism, or am I confusing these with something else (ie. monoblocks)?

[T2Andy]

The noises can be easily cured just needs tweaking
not got around to it yet

[90quattrocoupe]

This all bolts tohether quite nicely but bottom line is that it doesn't quite fit

The main trouble is that the 323 disc is just a little too big in that it rubs on the sprung clips AND (when heated up under normal braking) on the inside edge of the caliper body!

Combined with some rubbing on the splash plates this led to all sorts of unpleasant noises after th rebuild.

Derek.

Here is what I did being a shade tree mechanic.

I bent the ends of the guide pin fingers down in the direction of the pads. This raised the center of the guide pin body up enough to clear the rotors. No scraping.

There are a couple of high places on the splash guard. Take the guard off and flatten out the raised portion of the guard with a hammer. You probably also noticed that the 996 caliper does not fit in the same area of the cut out in the splash guard as the G60 brake does. I cut out the area to fit.

I have no scraping in over a year, and these rememdies were a lot cheaper than having the rotors turned.

Greg W.

[Mikes2]

So - does anyone know of someone in central scotland who can machine 5mm or so off my discs?!?!? Hopef this will clear up the noise issues.

Derek.

I used Newmarket engineering in Stirling to get discs machined.