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Fast28
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Joined: Feb 05, 2003
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Location: Gloucestershire UK

PostPosted: Sat Apr 10, 2010 7:07 pm Reply with quote Back to top

A project i've been working on over this winter...



After a few tip-offs and research I've found a reasonably cheap brake upgrade. The parts are based around the Ford Focus RS (1st gen) front discs that are 324mm x 28mm thick. These are as you can see 4 stud and being the older Focus come in a PCD of 108mm, same as the B3/B4 Audis.

The calipers I bought for around 220 from eBay, they were in very good condition and looked as though they had been refurbished at some point, they also came with a brand new set of Yellow-stuff pads. The calipers are Brembo 4 pots with a 44mm and 40mm sized pistons. These particular calipers came from a BMW 7 series V8. The real clincher was they also use a 324mm disc albeit 30mm width rather than 28mm but that's the only trade-off. The eBay seller bought these originally to go on his 3 series 330i but they weren't plug'n'play. I've painted them red with caliper high temperature enamel and put some new Brembo decals on to smarten them up.

The calipers obviously need mounting and after taking a few measurements I drew up a bracket design to mount them to the hubs. The material I bought off eBay for 20, it's bright mild steel. I am lucky to know a work colleague who has a small workshop in his garage and is quite handy on a mill and lathe as well as being an excellent welder, he welded my custom downpipes for the 30v transplant engine in the cabriolet. The brackets were machined and were a good fit.



I just had to file a section for them to clear the hub cylinder.

The brake discs also needed a visit to the lathe as the central mounting hole was too narrow to fit over the Audi hub mounting, just a few mm needed taking off.

The brake lines I had floating around and are Goodridge rear Audi coupe quattro lines ( S2/20v/2.8 ) and are just about the right length.

The extra four high tensile bolts are for mounting the calipers to the brackets.

In order to fit these I need to run 20mm wheel spacers for my alloy wheels to fit over the brakes, different wheels could possibly mean a lesser width spacer.

I've only trial mounted the brakes but due to running the spacers and 17 x 8" alloy wheels with 235 section tyres I've run into a temporary problem that the tyre contact area is just protruding beyond the wheel arch which is as far as I can tell an MOT failure item. It seems that the MOT criteria on this area which has been dictated by European law states that the wheel itself can protrude from the bodywork (wheel arch) by no more than 30mm but the tyre tread must be covered by the (wheelarch). I was thinking of maybe getting the arches rolled and flared but first I'll try some 215 section tyres and see if the tyre tread falls within the wheel arch. Cool

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2.8 Cabriolet Final Edition
30v

| Brembos | 993 mirrors | Keskin KT4 | H&R Cup | RS2 front | Jetex | 
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8690q
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PostPosted: Mon Apr 12, 2010 8:57 pm Reply with quote Back to top

Nice work.
It's guys like you doing the hard work and posting on this forum that make things possible for a numbnut like me Laughing
I'm ok with any like for like swap anywhere on the car but my head always gets pickled with this kind of fancy stuff.

Michael
 
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cq20v
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PostPosted: Mon Apr 12, 2010 9:01 pm Reply with quote Back to top

Great post this - well done sir! Very Happy

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istoo
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PostPosted: Tue Apr 13, 2010 6:21 pm Reply with quote Back to top

wopnderful, you alwasy make it look so as a matter of fact easy. enviable...

And how do they compare most importantly!

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Fast28
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PostPosted: Wed Apr 14, 2010 9:20 am Reply with quote Back to top

istoo wrote:
wopnderful, you alwasy make it look so as a matter of fact easy. enviable...

And how do they compare most importantly!


I've not fitted them yet but as soon as I can get some narrower tyres swapped over to keep things legal and MOT proof I'll mount them up. Smile

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2.8 Cabriolet Final Edition
30v

| Brembos | 993 mirrors | Keskin KT4 | H&R Cup | RS2 front | Jetex | 
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bikerjim
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PostPosted: Wed Apr 14, 2010 10:44 am Reply with quote Back to top

This is a great thread, thank you. Can you get some pics of the finished article and of how the wheels sit with the arches.

Nice work Exclamation

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Fast28
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PostPosted: Wed Apr 14, 2010 3:33 pm Reply with quote Back to top

I will indeed be updating this thread as things progress. My wheels tend to stick out because of a number of factors such as alloy width (8"), tyre width (235/40 17) and design of alloy wheel, spokes that tend to bend outwards and more flush with the face of the rim would be better, as mine have a deeper dish they are not so easy to fit around the caliper, hence the 20mm spacer.

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2.8 Cabriolet Final Edition
30v

| Brembos | 993 mirrors | Keskin KT4 | H&R Cup | RS2 front | Jetex | 
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skid
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PostPosted: Thu Oct 28, 2010 2:48 pm Reply with quote Back to top

How did you get on with the tyres dude?
 
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Fast28
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PostPosted: Thu Oct 28, 2010 10:00 pm Reply with quote Back to top

Brakes have been fitted a while now and WOW! Twisted Evil

I put on a set of 225 width tyres and I got a small amount of rubbing so had the arches rolled and inner plastic liners trimmed back, everything's good now Smile .

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2.8 Cabriolet Final Edition
30v

| Brembos | 993 mirrors | Keskin KT4 | H&R Cup | RS2 front | Jetex | 
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istoo
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PostPosted: Fri Oct 29, 2010 8:26 am Reply with quote Back to top

stops as well as it goes then?

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Andy10v
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PostPosted: Sat Oct 30, 2010 9:12 pm Reply with quote Back to top

Have the discs got a fairly low hat height that is pushing the caliper out?

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Fast28
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PostPosted: Sun Oct 31, 2010 7:00 pm Reply with quote Back to top

Andy10v wrote:
Have the discs got a fairly low hat height that is pushing the caliper out?


Yes, the discs have a lower hat height plus my wheels have a deep rim that brings the spokes closer to the caliper.

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2.8 Cabriolet Final Edition
30v

| Brembos | 993 mirrors | Keskin KT4 | H&R Cup | RS2 front | Jetex | 
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ratmin69
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PostPosted: Mon Nov 22, 2010 1:21 am Reply with quote Back to top

Nice one for this, might well look into this for my Turbo Cabby as i may need a brake upgrade with the WR in ! notworthy
Can i ask what offest wheels your using ?
 
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istoo
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PostPosted: Mon Nov 22, 2010 8:12 am Reply with quote Back to top

bumping this as well, fast would this clear an OEM 15in wheel or in theory would i need to go up a size?

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Fast28
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PostPosted: Mon Nov 22, 2010 12:30 pm Reply with quote Back to top

I used the standard Audi offset of 35-37mm.

The brakes only just clear my 17" alloys Laughing I will have to get some photos up. I was planning to take a step-by-step photo how-to but in the excitement I lobbed the brakes on and forgot! Rolling Eyes They are nicely bedded in now and as well as looking the nuts the stopping power is immense, well compared to what I'm used to! Very Happy

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2.8 Cabriolet Final Edition
30v

| Brembos | 993 mirrors | Keskin KT4 | H&R Cup | RS2 front | Jetex | 
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Greavesy
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PostPosted: Mon Apr 30, 2012 11:47 am Reply with quote Back to top

Would I be able to fit a set of these discs with a set of G60 calipers?
 
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gripper
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PostPosted: Thu May 03, 2012 11:24 pm Reply with quote Back to top

A bit late but do you have a pic of the finished article Embarassed

Thinking of having a go at this conversion, book marked your excellent write up for future consideration Cool

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gripper
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PostPosted: Tue Apr 23, 2013 5:31 pm Reply with quote Back to top

Any more info on this Si ?

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Tom_
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PostPosted: Tue Jun 11, 2013 2:25 pm Reply with quote Back to top

Perfect job.Thank you

Few questions:

1)Do u have a oem numbers of calipers and pads?
2)Do u sell calipers + brackets?
3) So i can used a Focus RS brake discs and BMW 7 V8 brake discs with redrill
4) Should your friend make another brackets?

Thanks lot
 
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Fast28
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PostPosted: Sat Jun 15, 2013 4:55 pm Reply with quote Back to top

Tom_ wrote:
Perfect job.Thank you

Few questions:

1)Do u have a oem numbers of calipers and pads?
2)Do u sell calipers + brackets?
3) So i can used a Focus RS brake discs and BMW 7 V8 brake discs with redrill
4) Should your friend make another brackets?

Thanks lot


This was just a one off project, I don't sell or manufacture any parts. To be honest if you're looking for a brake upgrade it's a lot simpler to upgrade to five stud hubs and Porsche Brembo brakes, the parts are readily available and there are people who machine the brackets.

You can only use the Focus disks as they are 4-hole in the right PCD of 108mm.

Caliper part numbers and details can be found here:-

http://www.brakepartssuperstore.org.uk/contents/en-uk/d5103.html

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2.8 Cabriolet Final Edition
30v

| Brembos | 993 mirrors | Keskin KT4 | H&R Cup | RS2 front | Jetex | 
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Tom_
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PostPosted: Sun May 04, 2014 5:42 pm Reply with quote Back to top

Please guy, do you have these measurments? Thank You

 
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Tom_
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PostPosted: Sun Aug 09, 2015 12:35 pm Reply with quote Back to top

Fast28 wrote:
Tom_ wrote:
Perfect job.Thank you

Few questions:

1)Do u have a oem numbers of calipers and pads?
2)Do u sell calipers + brackets?
3) So i can used a Focus RS brake discs and BMW 7 V8 brake discs with redrill
4) Should your friend make another brackets?

Thanks lot


This was just a one off project, I don't sell or manufacture any parts. To be honest if you're looking for a brake upgrade it's a lot simpler to upgrade to five stud hubs and Porsche Brembo brakes, the parts are readily available and there are people who machine the brackets.

You can only use the Focus disks as they are 4-hole in the right PCD of 108mm.

Caliper part numbers and details can be found here:-

http://www.brakepartssuperstore.org.uk/contents/en-uk/d5103.html
Hi, thank for the numbers. I just finished the same brembo 4 pistons replacement, but i have a question.Now the brake pedal going to easy and its a long way, when the brakes comes...Did you change a brake cylinder master?Or you ran a OEM? I have 20V Coupe
 
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Ilkorin
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PostPosted: Thu Sep 10, 2015 10:58 am Reply with quote Back to top

Sorry to drag up an old thread, were dimensions for this bracket ever shared? It would be awesome if I could get these as I'm doing the same conversion! Would save a heck of a lot of trial and error!
 
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