Posts Tagged ‘ Big Brake Kit ’

Big Brake Kits

Big Brake Kits are becoming more and more popular, especially the offerings from D2 and K Sport due to their price point and build quality. They offer immense stopping ability and the most popular sizes are 330mm and 356mm designed to fit under 17″ and 18″ wheels respectively, although in some instances a narrow wheel spacer may be required, depending on the wheels fitted.

D2 kits feature 6 pot calipers with road seals and cross drilled belled discs, K Sport calipers are 8 pot and use 8 grooved discs and are available in a range of caliper colours at no extra cost; Black, Red, Yellow, Orange (K Sport only), Purple (D2 Only).

Prices range from £899 – £1122. Avaiable for Astra G, Astra H, Corsa D, Vectra C, Zafira A, Zafira B, Vectra B

D2 6 Pot Caliper in Purple

D2 6 Pot Caliper in Purple

K Sport 8 pot Caliper in Orange

K Sport 8 pot Caliper in Orange

D2 6 Pot Caliper in Purple

D2 6 Pot Caliper in Purple

D2 Brake Kits

We had a couple of cars in recently for D2 big front brake upgrades, both receiving D2 6 Pot kits with 330mm alloy belled discs to fit under 17″ Alloy Wheels:

Purple Calipers:

D2 6 Pot 330mm Brake Kit

D2 6 Pot 330mm Brake Kit

Red Calipers:

D2 6 Pot 330mm Brake Kit

D2 6 Pot 330mm Brake Kit

Also available with 356mm discs to fit under 18″ Alloy Wheels.

Kit prices start at £1022.00 including DOT5.1 braked fluid, discs, bells, calipers, brackets, bolts, shims and braided front brake hoses.

Astravan 1.9 CDTi Stage 3+ Tuning Package

We had this Astravan 1.9CDTi here recently for a few days undergoing some fairly extensive upgrades to cover the engine, brakes  and chassis.

Performance:
A Stage 3+ conversion. The van was fitted with our hybrid turbo charger, full 2.5″ stainless steel exhaust system (turbo back), full height CSRacing Intercooler and 80mm Air Flow Meter with revised inlet air path. At the same time an oil and filter change was also carried out.

After the hardware had been fitted, it was round onto the rolling road for ecu remapping and a full set up, which achieved 223bhp and 377 lb ft torque.

Astravan 1.9CDTi 150

Astravan 1.9CDTi 150

Braking:
At the same time a K Sport big brake kit was fitted, under the 17″ wheels, to greatly improve the stopping ability over the original factory 308mm brake set up. Red 8 Pot calipers, 330mm x 32mm 8 grooved and ventilated front discs with EBC Yellow Ceramic Pads. The brake system was bled through with DOT 5.1 brake fluid.

K Sport 8 Pot 330mm Brake Kit

K Sport 8 Pot 330mm Brake Kit

To ensure adequate clearance between the wheel spokes and the calipers a TÜV approved 3mm spacer has been fitted with longer 28mm black wheel bolts.

Handling:
The van has also had our Courtenay Sport Clubman Plus fast road suspension upgrade which is a full kit that includes original equipment (OE) genuine Astra VXR dampers and a set of DAP Road springs, which drops the chassis significantly, as can be seen on the before and after pictures below. Ideal for fast road and light track day use.

Before:

Astravan 1.9CDTi Standard Suspension

Astravan 1.9CDTi Standard Suspension

After:

Astravan 1.9CDTi Clubman Plus Suspension

Astravan 1.9CDTi Clubman Plus Suspension

Big Brake Kits – Caliper Maintenance

Preventative Maintenance is always more cost effective in the long term as it prevents smaller issues from becoming more major problems. Take for example ‘Big Brake Kits’ which are now more commonly fitted on road cars and feature 4 pot, 6 pot and 8 pot calipers.

These calipers are aluminium for lightness and strength. Usually they are fitted to race cars which never see any road use and are therefore not subjected to the same harsh environment as cars that are used on the road. Salt and aluminium do not mix well, and will over time cause corrosion. Race cars never experience this phenomena.

Regular checking and maintenance of this type of brake caliper is essential. Race cars frequently have pads removed, inspected, replaced and calipers are cleaned regularly, but road cars do not have quite the same ‘affection’ lavished upon them.

Take for example the K Sport 8 pot calipers. We have seen a few instances with some of these calipers where salt from over-winter use has penetrated under the pad sliders causing them to lift and so in turn if left the pad can seize in the caliper – even calipers that are painted or anodised can suffer. With this in mind it is always a sensible precaution to inspect these brakes after winter to clear away traces of salt and corrosion, and also a pre-winter check will pay dividends too.

Remove the pads to check they are not seizing into the calipers. If there is corrosion evident then the upper and lower sliders will need to be removed. This is easier to do with the caliper on a workbench, so remove the brake hose from the caliper (take care with brake fluid leaking) and the caliper from the car. Remove the upper and lower sliders, clean around and underneath them to remove traces of any dirt and/or corrosion, clean the sliders using a wire wheel, coat both the sliders and their seats with some high temperature anti-seize aluminium spray, such as Wurth AL1100, as this will help to prevent further salt ingress and over winter corrosion. It will also help keep the pads moving freely in the calipers. Refit the calipers, brake lines and reassemble with the pads, assuming they are serviceable. Replace the pads if required, then bleed thoroughly.

When carrying out this work you will also need to have 8 x M6 x 1.0 x 12mm A2 button head stainless steel screws available, which retain the sliders. The ones fitted in the KS calipers from factory are prone to corroding and the heads rust. This can make them difficult to remove if the heads round off, meaning additional labour time, effort and frustration to get them out!!

Whilst this will take a few hours to do properly, it is more than worth it – leaving it until the pads seize will only mean a nightmare of a job later on down the line.

The Courtenay Sport Blog

%d bloggers like this: