Custom front and rear big brake kit

Suspension and other discussion

Postby Denver_whiteST185 » Tue Mar 25, 2008 2:17 am

very nice

what size and offset are your wheels btw
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^Ted^

went back to the dark side of hondas!!!
(not really, i just own a completely UNmodified 91 civic dx that gets 45+ mpg now)
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Postby gt4rcdude » Tue Mar 25, 2008 11:48 am

Denver_whiteST185 wrote:very nice

what size and offset are your wheels btw


Thanks and 17x8 +35 Enkei RPF1's 15.5lbs each. 225/45-17 Falken RT615's.
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Postby CMS-GT4 » Tue Mar 25, 2008 2:30 pm

Its a shame no one offers those rear hats for sale.
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Postby Denver_whiteST185 » Tue Mar 25, 2008 4:28 pm

CMS-GT4 wrote:Its a shame no one offers those rear hats for sale.


it really is. That would really take out the hardest part of building a kit like yours or getting rotors adapted correctly for ST205 calipers so that the front and rear are correct bolt ons without centerbore or offset problems.
^Ted^

went back to the dark side of hondas!!!
(not really, i just own a completely UNmodified 91 civic dx that gets 45+ mpg now)
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Postby CMS-GT4 » Tue Mar 25, 2008 4:37 pm

Maybe we should harass Conrad into a group buy.
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Postby Denver_whiteST185 » Tue Mar 25, 2008 6:45 pm

well, i would want the hats to work with these (or something with the same specs - 297x32)

http://www.racingbrake.com/LEXUS_FRONT_ ... 01-351.htm

if they bolted on to the hat, and could be centered correctly, st205 front calipers would be a bolt on application. the only thing really needed for the rear 205 brakes would be a custom ring to adjust the bore, which would be easy to machine, and you can get rear st205 rotors for $100/rotor through www.japanparts.com
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went back to the dark side of hondas!!!
(not really, i just own a completely UNmodified 91 civic dx that gets 45+ mpg now)
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Postby Luni » Tue Mar 25, 2008 9:58 pm

John, tell your buddy to get off his ass and make these kits for people.

He could make a bit of money for this.

There are quite a few swapped 5th gen celicas and alltracs running around.
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Postby gt4rcdude » Tue Mar 25, 2008 11:30 pm

Denver_whiteST185 wrote:well, i would want the hats to work with these (or something with the same specs - 297x32)

http://www.racingbrake.com/LEXUS_FRONT_ ... 01-351.htm


These rotors are $100 a pair more than the Wilwoods', FYI.


And OMFG I can't imagine making a kit. It's a cubic assload of work (one cubic assload=one million sh*tloads)! I can give everybody the numbers once I'm all finished and the system is proven.
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Postby Denver_whiteST185 » Wed Mar 26, 2008 12:03 am

gt4rcdude wrote:
Denver_whiteST185 wrote:well, i would want the hats to work with these (or something with the same specs - 297x32)

http://www.racingbrake.com/LEXUS_FRONT_ ... 01-351.htm


These rotors are $100 a pair more than the Wilwoods', FYI.



thats why i said something with the same specs would work too :)

that size rotors will let the ST205 calipers bolt on, provided they are centered and everything. i have measurements somewhere of the stock st205 front rotors if needed, and the guy who has my old set now could probably take new measurements of the rotors and the calipers if you need to know specific specs.

i really doubt i would be in the market anytime soon, but there are people who want better brakes who would be buyers on those hats. it would make it easy to let anyone can make a cheap big brake kit especially if they use the stock calipers kinda like the powerslot kits. if you asked, you could probably get some old stock rotors donated to start a "core" program or something.
^Ted^

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(not really, i just own a completely UNmodified 91 civic dx that gets 45+ mpg now)
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Postby gt4rcdude » Wed Mar 26, 2008 12:38 am

Gotcha.

I learned the hat is the key. Had we made a custom unit, we could have stayed on the same "plain" as the original rotor. A small advantage of moving the rotor back .200" was giving extra clearance for the caliper. In moving the rotor back we had to stick with the 25mm thickness. Too many clearance issues in all directions to try a 32mm.

With the price and availability of 205 calipers I went with the Wilwoods. The weight reduction was a huge bonus. We just didn't have the time or will to make custom hats. I originally wanted to use 205 calipers. They're drop dead beautiful. Wilwood had blueprint type drawings online. I didn't have a set of 205's to measure and I sure wasn't going to buy a set not knowing they'd work. With the dollar worth as much as a peso overseas it was just too cost prohibitive.
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Postby Denver_whiteST185 » Wed Mar 26, 2008 1:14 am

gt4rcdude wrote:Gotcha.

I learned the hat is the key. Had we made a custom unit, we could have stayed on the same "plain" as the original rotor. A small advantage of moving the rotor back .200" was giving extra clearance for the caliper. In moving the rotor back we had to stick with the 25mm thickness. Too many clearance issues in all directions to try a 32mm.

With the price and availability of 205 calipers I went with the Wilwoods. The weight reduction was a huge bonus. We just didn't have the time or will to make custom hats. I originally wanted to use 205 calipers. They're drop dead beautiful. Wilwood had blueprint type drawings online. I didn't have a set of 205's to measure and I sure wasn't going to buy a set not knowing they'd work. With the dollar worth as much as a peso overseas it was just too cost prohibitive.


well, the beauty of having custom made hats is that if someone wants to do something compleatly different, like STI or EVO brembos, porsche monoblocks, wilwoods, whatever. this way they'll just need a rotor ring that suits that application, make a bracket for their calipers if nessissary, and wala, they can upgrade their brakes, and if they want to make it fit under 15" wheels, 16" wheels, or they HAVE to have the biggest kit money can buy, they can get some huge 10 piston custom calipers. it would really open up options and make it easier for a DIYer since there aren't that many options for our cars.
^Ted^

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(not really, i just own a completely UNmodified 91 civic dx that gets 45+ mpg now)
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Postby gt4rcdude » Thu Mar 27, 2008 12:21 pm

Fronts are done!


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The last of the rear stuff is arriving tomorrow. With any kind of luck I'll be testing this weekend.
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Postby turbo4wd » Thu Mar 27, 2008 7:28 pm

So far the setup looks great.. 8)

Now it just has to perform.. :wink:

Can't wait to hear about the results.. :D
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Postby 88st165 » Thu Mar 27, 2008 10:49 pm

wow :shock: amazing work!

what kind of driving are you doing that would require brakes of this magnitude?

is 17" the minimum dia wheel you can use?
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Postby gt4rcdude » Fri Mar 28, 2008 11:08 pm

It's a wrap! Stick a fork in it! Done. Finished.

Good god that was hard work and a lot of headache. But boy was it worth it. It's ridiculous the braking power. The car stops HARD!!!

Here's the rear bracket:
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Here's the back of the rear brakes safety wired up with my feet in the background :) :
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And here's the finished product!!!!!!

Fronts:

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Rears:

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And of course the whole car:

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I'd like to thank my friends Randy and Lisa. I couldn't have asked for better friends. Randy is an amazing machinist who's level of precision astounds me. I'm owe him big time.
Last edited by gt4rcdude on Fri Mar 28, 2008 11:31 pm, edited 1 time in total.
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