Inexpensive DIY Big Brake Kit
 

So i was inspired by Swift996's wrx brakes to research Wilwood brakes, and I realized i could build a similar kit at maybe a reduced price. As stated in the linked thread, I do not intend for it to be a track monster. I just want a comparatively inexpensive, featherweight setup that would work well on the street.


I began by taking measurements of the wheel carrier and the stock rotors, which gave me a template for brackets that would mount Wilwood calipers at the appropriate location for the 2 piece rotor.

Some CAD:
http://i.imgur.com/xEMtYmK.jpg?1

Some FEA:
Applying 20000N force where caliper mounts to bracket. This corresponds to approximately 1.6g of braking decceleration, assuming 70% weight transfer to the front axle and a coefficient of friction of 1 between the road and tires.

http://i.imgur.com/jgoBuqm.jpg


Stress profile looks good, Al 6061 has a yeild strength of roughly 275 MPa, so we have a factor of safety of above 3, which is also great...

http://i.imgur.com/z3jwklo.jpg?1

Wilwood forged dynalite calipers :
http://i.imgur.com/3GJyolZ.jpg

Failed prototypes:
http://i.imgur.com/u5dtSbI.jpg
These had wrong hole placements. The caliper was in such a position that the brake pads ended up 1mm outside the outer edge of the rotor.

Lasercut prototypes in wood:
http://i.imgur.com/k3wnZch.jpg
Perfect. Revised the design a little to go back to the original shape.
Final brackets would be cut on a waterjet.

Final Product:
http://i.imgur.com/kVTIo67.jpg
http://i.imgur.com/BWB7w0k.jpg

I will install these on the FRS tomorrow, Should be an interesting day...

I love projects like this!

Forgot to add prices:
Caliper : WIL-120-6811 $125 X2 = $250
Rotor Hats : WIL-170-9206 $125 X2 = $250
Rotor Discs : WIL-160-0277 $33 X2 = $66
Brake pads BP10 : WIL-150-8850K $42
Brake lines : WIL-220-9288 $60
Brackets : $100

TOTAL : $768

Cool project! Willing to share your design? I could probably get a bracket like yours cut up at work...

Unless you're in the business of selling the bracket/making kits?? Works for me too. :thumbsup:

I have an ESAB plasma / water jet CNC cutter at work and have been thinking about this for awhile now.

This and license plate relocation kits.

Cool Project. If willing to share design I could get literally hundreds of these made next week. Because of the holidays we have a production shutdown and are only doing projects at work.

Here is a snapshot of my design. Just replace the 8mm holes by 10mm and the 10mm holes by 12mm and you shall have a perfect part.

I am not in the business of making these brackets, not by any means.
I had a shop near work make them for me, so i can get them made again for anyone who wants a pair.

http://i.imgur.com/BQwSiH6.jpg

If you end up making money on these hundreds, could you send me a couple? The taper on the water jet cut screwed up the holes on one of my pieces (the guy stacked my 2 work pieces and made 1 cut), so my 10mm holes have to be 11mm on that one piece for everything to line up properly. I haven't done GD&T at all on this thing...

By the way, the piece is 3/4" thick.

subbed.

Would be interested in some brackets.

Cool! I've always been meaning to get into the garage and start taking measurements, but these base measurements are SO helpful if one even wanted to make brackets for other calipers.

Should be pretty quick and easy to convert and fire off a DXF to the shop. I just wish it wasnt winter around here, otherwise I'd be so much more productive with the car lol...

Thanks again!

Subbed and definitely in for a couple pair of brackets.

Stopping performance vs Std Brakes?