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12-19-2014, 08:15 PM | #1 |
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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: 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. 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...
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FR-S Mod target: 200 BHp / Tonne 4lb Li Battery, RPF1 17x9, 245 RE71R, RCE T2, OFH, OFT Stg 2, Berk Over+Front Pipe, , STI Eng/Trans Mts, PU Bushings, Forrester Liq-Liq oil cooler, Al Driveshaft, OSGiken Diff Last edited by 200hp/tonne; 12-19-2014 at 09:57 PM. |
12-19-2014, 08:23 PM | #2 |
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Wilwood forged dynalite calipers :
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FR-S Mod target: 200 BHp / Tonne 4lb Li Battery, RPF1 17x9, 245 RE71R, RCE T2, OFH, OFT Stg 2, Berk Over+Front Pipe, , STI Eng/Trans Mts, PU Bushings, Forrester Liq-Liq oil cooler, Al Driveshaft, OSGiken Diff |
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12-19-2014, 08:41 PM | #3 |
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Failed prototypes:
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: Perfect. Revised the design a little to go back to the original shape. Final brackets would be cut on a waterjet.
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FR-S Mod target: 200 BHp / Tonne 4lb Li Battery, RPF1 17x9, 245 RE71R, RCE T2, OFH, OFT Stg 2, Berk Over+Front Pipe, , STI Eng/Trans Mts, PU Bushings, Forrester Liq-Liq oil cooler, Al Driveshaft, OSGiken Diff |
12-19-2014, 08:44 PM | #4 |
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Final Product:
I will install these on the FRS tomorrow, Should be an interesting day...
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FR-S Mod target: 200 BHp / Tonne 4lb Li Battery, RPF1 17x9, 245 RE71R, RCE T2, OFH, OFT Stg 2, Berk Over+Front Pipe, , STI Eng/Trans Mts, PU Bushings, Forrester Liq-Liq oil cooler, Al Driveshaft, OSGiken Diff |
12-19-2014, 09:10 PM | #5 |
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I love projects like this!
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The Following User Says Thank You to CSG Mike For This Useful Post: | Jaden (12-20-2014) |
12-19-2014, 09:26 PM | #6 |
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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
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FR-S Mod target: 200 BHp / Tonne 4lb Li Battery, RPF1 17x9, 245 RE71R, RCE T2, OFH, OFT Stg 2, Berk Over+Front Pipe, , STI Eng/Trans Mts, PU Bushings, Forrester Liq-Liq oil cooler, Al Driveshaft, OSGiken Diff |
12-19-2014, 10:58 PM | #7 | |
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Quote:
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. |
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12-19-2014, 11:26 PM | #8 |
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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. |
The Following User Says Thank You to GotBRZ1691 For This Useful Post: | DAEMANO (12-20-2014) |
12-19-2014, 11:45 PM | #9 |
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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.
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FR-S Mod target: 200 BHp / Tonne 4lb Li Battery, RPF1 17x9, 245 RE71R, RCE T2, OFH, OFT Stg 2, Berk Over+Front Pipe, , STI Eng/Trans Mts, PU Bushings, Forrester Liq-Liq oil cooler, Al Driveshaft, OSGiken Diff |
The Following 6 Users Say Thank You to 200hp/tonne For This Useful Post: | DAEMANO (12-20-2014), hmong337 (12-21-2014), Kiske (12-20-2014), Manji (12-20-2014), SomeoneWhoIsntMe (12-20-2014), Sportsguy83 (12-20-2014) |
12-19-2014, 11:56 PM | #10 | |
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Quote:
By the way, the piece is 3/4" thick.
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FR-S Mod target: 200 BHp / Tonne 4lb Li Battery, RPF1 17x9, 245 RE71R, RCE T2, OFH, OFT Stg 2, Berk Over+Front Pipe, , STI Eng/Trans Mts, PU Bushings, Forrester Liq-Liq oil cooler, Al Driveshaft, OSGiken Diff |
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12-20-2014, 01:41 AM | #11 |
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subbed.
Would be interested in some brackets. |
12-20-2014, 02:32 AM | #12 | |
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Quote:
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! |
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12-20-2014, 06:20 AM | #14 |
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Stopping performance vs Std Brakes?
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