Posts Tagged ‘ K Sport ’

Astra H VXR Upgrades

Here we have a couple of Astra H VXRs in for upgrade.

The black car has had a K Sport 8 Pot 356mm front brake kit, CSRacing intercooler, full 3″ exhaust system and inlet plenum fitted and will be mapped and set up on the rolling road. It is also having a rear cage fitted along with eyelet provision for harnesses.

The blue car has had a Stage 3 package (CSRacing intercooler, full 3″ exhaust system), direct route hose kit and airbox, a Courtenay Turbosmart recirculation valve and a Quaife LSD and is also due to be mapped and set up on the rolling road.

Workshop Astra H VXRs

Workshop Astra H VXRs

Astra H VXR Stage 4 K06 Coversion

Another fabulous conversion on an Astra H VXR.

This car first came to us for mapping to Stage 3 (hardware requirements are a full 3″ exhaust system and uprated intercooler). The car was fitted with a Forge lower front mount intercooler, but on the exhaust side only had a pre-cat removal pipe, and a Piper 3″ cat back exhaust system and was still running the factory main cat section. Obviously with this restriction in place it would be down on expected power, and upon checking on the rolling road this was found to be the case, but still making a respectable 283bhp.

Remedial action was simple; fit a 3″ front pipe and sports cat section. Once the mapping was finalised the results were a very good 299.99bhp and 332 lb ft torque on a cold January day.

In the hunt for more power, the car returned to us recently for a full K06 and inlet manifold upgrade.

ZRP steel rods and uprated ARP rod bolts were fitted, stem seals and retainers were done at the same time, and then when being put back together the K06 turbocharger, Courtenay Turbosmart uprated actuator, Courtenay Klasen high flow inlert manifold,thermal inlet gasket and high flow 340 fuel pump were all fitted. This was also the ideal opportunity to replace the cambelt and water pump and fit a lightweight allow bottom pulley.

Z20LEH engine being fitted with steel rods

Z20LEH engine being fitted with steel rods

An uprated CSRacing clutch kit and lightweight billet steel flywheel were also fitted, as a safeguard against the increase in power and torque, and to top it off a huge K Sport 8 Pot 356mm brake kit was also fitted, to bring everything safely to a halt. The car already had a Wavetrac LSD in the gearbox.

Rolling Road Mapping

Rolling Road Mapping

The end results after mapping 333bhp and 350 lb ft torque.

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

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.

Pagid RS29 Pads Available

Pagid RS29 Pad
Pagid RS29 Pad

For the serious fast road and track day enthusiasts who appreciate an excellent brake pad, we now have in stock Pagid RS29 pads for the following calipers:

AP (VXR) 6 Pot (used in 362mm Vectra VXR kit)
Alcon 4498 4 Pot Monoblock calipers (used in the Alcon Xtreme Brake Kits)
K Sport 8 Pot (356mm and 330mm kits)
D2 6 Pot (356mm and 330mm kits)

These Pagid pads are also available from us for the AP 4 Pot 6600 caliper, and also the AP 4 Pot VXRacing 6600 caliper (343mm discs) which uses a slightly slimmer D50 pad.

From our own testing and from customer feedback, these Pagid pads are an excellent trackday brake pad and extremely well suit to that environment, that also works well for fast road use, benefiting from good feel even from lower temperatures.

Pad Spec.
Friction Level:
Cold 0.40
At 100o C – 0.43
At 300o C – 0.47
Max At 550o C – 0.49

Constant Working Temperature: 400-700o C
Maximum Temperature: 750o C (Short Period Only)

Pads range from £240.00 – £290.00

RS29 is a direct development of RS19, with a very similar friction coefficient to RS19, improvements in initial bite offering quicker response and slightly more temperature stable at the upper levels of the temperature range. Developments in raw material selection and compounding have resulted in improvements also in pedal feel and feedback, helping with modulation particularly on lighter applications.
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