A few weeks ago I ordered some discs from Wilwood. I wanted an affordable big brake kit that included the rear. In order to save money, time and headache I decided to use the stock calipers. The mechanical advantage of the larger rotors combined with the added thermal capacity should net a big improvement.
Major progress the last few days. Went up to NJ to help with the machining. The first picture is the stock front rotor on the lathe being turned down to make it into a rotor hat.
First cuts were to get to the proper outside diameter to fit inside the new disc.
Now cutting down the back of the rotor:
Internal cooling fins: (yes, these were nearly new Brembo rotors)
This is the new rotor on it's new hat before we drilled the mounting holes:
327mmx25mm
The rear rotor was cut down the same way. Here we are cutting down the back of the rotor to give the new disc a true surface to mount.
On the milling machine getting the mounting holes:
The holes all done. This is when we realized the bolt heads interfered with the bell of the rotor:
Back on the milling machine for some sexy slots for clearance:
This is a crummy shot of the trial fit of the rear disc. The rear rotor is only 1/4 of an inch larger than the stocker, however I now have a 2 piece rotor with a replaceable $66 disc.
ADDED: These discs ended up not working out. They foul the dust shield too much.
We did both sides of the car simultaneously. Of course grade 8 bolts will be used. I'll probably end up just painting the hats. Powder coat would add too much thickness and anodizing isn't an option. Next engineering feat will be the caliper mounting system.
More to come. . .
Major progress the last few days. Went up to NJ to help with the machining. The first picture is the stock front rotor on the lathe being turned down to make it into a rotor hat.
First cuts were to get to the proper outside diameter to fit inside the new disc.
Now cutting down the back of the rotor:
Internal cooling fins: (yes, these were nearly new Brembo rotors)
This is the new rotor on it's new hat before we drilled the mounting holes:
327mmx25mm
The rear rotor was cut down the same way. Here we are cutting down the back of the rotor to give the new disc a true surface to mount.
On the milling machine getting the mounting holes:
The holes all done. This is when we realized the bolt heads interfered with the bell of the rotor:
Back on the milling machine for some sexy slots for clearance:
This is a crummy shot of the trial fit of the rear disc. The rear rotor is only 1/4 of an inch larger than the stocker, however I now have a 2 piece rotor with a replaceable $66 disc.
ADDED: These discs ended up not working out. They foul the dust shield too much.
We did both sides of the car simultaneously. Of course grade 8 bolts will be used. I'll probably end up just painting the hats. Powder coat would add too much thickness and anodizing isn't an option. Next engineering feat will be the caliper mounting system.
More to come. . .