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Courtenay Sport Brake Kits

Courtenay Sport have joined forces with leading brake manufacturers, to design a range of uprated brakes that will provide optimum performance without warping. They are effective from cold, don't squeal at low speeds and stay fade free at very high temperatures, ideal for all fast road and track day applications.
How do 'normal' brake discs work?
As the brakes work the wearing of the pads and discs create a dust between them, thereby reducing 'feel' and responsiveness to light pressure. Also, when the pads get very hot under hard braking they release gas from the friction surface which 'lifts' the pad off the surface of the disc. To overcome the resultant fade you push harder, increasing the heat, increasing the gas... and so on.

Courtenay Sport Performance Brakes

Courtenay Sport use brake components from well known and respected manufacturers, who not only supply components for aftermarket use, but also supply to manufacturers for OE fitment and are used for motorsport applications. Our bigger brake kits are ideal for fast road and track day use and will dramatically improve your cars stopping ability giving the driver greater feel and confidence. Furthermore the brakes that we offer here are tested on our own cars, to ensure that we only offer a set up that we are happy to choose ourselves.

Courtenay Brake Disc Conversion Kits

308mm 5 Stud Brake Kit

Courtenay's 308mm 5 stud brake kit is available for the Astra G/H and Vectra B. Once fitted the kit provides a huge increase in stopping power due to the increased leverage of the 308mm disc, over the standard smaller discs.

The Astra & Vectra package consists of a pair of uprated discs and mounting brackets complete with new sliders. The brackets simply replace the OE items to space the caliper accordingly, whilst the discs replaces the original 280mm/288mm disc, picking up on all the standard fittings. New pads can be specified according to requirements from OE to uprated.

The kits are available with plain or grooved discs for maximum stopping power. Uprated pads are also available to further enhance and compliment the set up.

Prices

Astra H - 308mm kit - plain discs ... £220
Astra H - 308mm kit - Courtenay 16 groove discs ... £315 or with EBC Grooved Discs £275

Astra G - 308mm kit - plain discs ... £220
Astra G - 308mm kit - Courtenay 16 groove discs ... £315 or with EBC Grooved Discs £275

Vectra B - 308mm kit - plain discs ... £305
Vectra B - 308mm kit - Courtenay 16 groove discs ... £405 or with EBC Groved Discs £375

322mm 5 Stud Brake Kit - Astra G/H and Zafira A/B

322mm Brake Upgrade Full Size Image - Click Here
322mm Brakes
Courtenay Sport's 322mm Brake upgrade kit suitable for 5 Stud Astra G/H and Zafira A/B. Huge increase in stopping ability which will sit neatly under 17" alloy wheels. This upgrade kit includes a pair of 322mm vented discs, GM OE pads, braided brake lines, calipers and brackets finished in VXR blue.
322mm Brake Kit Complete
Vauxhall Retail £867.00 Our Price £580.00 inc VAT Buy Now Click Here!
includes Braided Front Lines. 16 Groove Discs +£76.95
322mm Brake Upgrade Full Size Image - Click Here
Under 17" Wheel

K Sport 8 Pot 330 and 356mm Brake Kit - Astra G/H, Zafira A/B, Corsa D, Vectra B, Vectra C

K Sport 356mm 8 Pot Brake Kit This kit comprises of a pair of 2 piece 356mm x 32mm 8 grooved discs with alloy bells, Lightweight Alloy K Sport 8 pot calipers, brackets and stainless steel braided front brake hoses. The calipers are machined from aircraft quality billet with machined grooves to protect the bridge link pipes and have alluminium pistons, high temp seals and stainless steel brake pad wear plates.

The calipers are finished in Black. Painted Red, Yellow or Orange available at no extra cost. Painted OPC Blue available as a cost option. Pads can be specified to suit requirements.
For Astra H, Zafira B, Astra G, Zafira A, Corsa D, Vectra B, Vectra C with suitable wheels.

Red Ceramic pads make a good fast road pad, Yellow Ceramic pads make good fast road and track day pads, whilst Blue ceramic pads are available for track/race use. Other pad compounds including Pagid RS29 and Ferodo DS2500 are available.

The lightweight caliper come in differential bore configuration. They are machined from aircraft quality billet and weigh just over 3kgs each, and have protection grooves machined in for the bridge tubes. Aluminum pistons, high temperature seals, and stainless steel brake pad wear plates are also standard on each caliper. The opposed piston caliper design greatly improves pad wear and caliper rigidity over the OE design. The stainless steel brake lines stop expansion under pressure.

The kit uses the 2-piece floating disc assembly which reduces weight both rotating and unsprung. The floating disc also stops thermal stresses of extreme heat from warping the disc or cupping the braking surface. The unique slot design on the rotor greatly reduces braking noise and expels gas and pad debris faster than conventional slot designs. Every rotor is always heat treated and balanced before shipment for the best possible performance.

This brake kit will fit under 18" Team Dynamics Pro Race 1.2 Wheels ET35mm and ET40mm, Standard 18" Snowflake Wheels and the optional 19" Astra VXR Wheel (clearance is close on the 19" wheel and a 3mm - 5mm spacer is suggested).

Kit Price £978.00 Buy Now Click Here! :: Fitting available in our workshop. Requires 18" wheels with correct offset for clearance.

330mm 8 Pot Kit £899.00

Replacement Pad Sets available from £122.50. Available Pad Compounds include: EBC Yellow and Blue Ceramic, Pagid RS29, Ferodo DS2500 and Performance Friction. Buy Now Click Here!

Replacement Discs 356mm £359.00 per pair Buy Now Click Here!

D2 6 Pot 330mm and 356mm Brake Kit - Astra G/H, Zafira A/B, Corsa D, Vectra B, Vectra C

D2 356mm 6 Pot Brake Kit D2 Racing big brake kits are designed to cope with the heat generated by extreme braking on the road or track. Where as the standard braking system will quickly overheat and no longer perform the D2 Racing brake kits will dissipate this heat so keeping the braking system within its operating parameters allowing you, the driver, to brake for much longer and much harder.

This kit comprises of a pair of 2 piece cross drilled discs with lightweight aluminium bells, lightweight strong aluminium 6 pot calipers, steel mounting brackets, stainless steel braided front brake hoses, fast road brake pads and 1L DOT5.1 Brake Fluid.

The calipers are CNC machined from aluminium with lightweight aluminium pistons and external dust seals. They have strong thick aluminium bridge supports that double up as pad retainers helping increase the rigidity of the calipers to prevent flex and maximise pedal feel and use one of the most popular pads shapes offering an excellent choice of pads.

The mounting brackets are cast from S45C steel and then CNC machined for strength and accuracy of fit.
The calipers are finished in painted Red; painted Black, Purple or Yellow are available at no extra cost. Other colour finishes are available at extra cost to special order.

The supplied pads are of a fast road/mild track day material specification but other pads can be specified to suit requirements at a small surcharge, depending upon the chosen pad. Optional pads include EBC Red, Yellow and Blue Ceramic, Ferodo DS2500, Pagid RS29

The disc sizes are 330mm or 356mm x 32mm.

Red Ceramic pads make a good fast road pad, Yellow Ceramic pads make good fast road and mild track day pads, whilst Blue ceramic pads are available for track/race use. Other pad compounds including Pagid RS29 and Ferodo DS2500 are available.

The 356mm kit will fit under 18" Team Dynamics Pro Race 1.2 Wheels ET35mm and ET40mm, Standard 18" Snowflake Wheels and the optional 19" Astra VXR Wheel (clearance is close on the 19" wheel and a 3mm - 5mm spacer is suggested which we can supply if required).

356mm 6 Pot Kit £1149.00 ::Fitting available in our workshop. Requires 18" wheels with suitable offset.

330mm 6 Pot Kit £1049.00

Replacement Pad Sets available from £122.50. Available Pad Compounds include: EBC Yellow and Blue Ceramic, Pagid RS29, Ferodo DS2500 and Performance Friction.

Replacement Discs 330/356mm £359.00 per pair
D2 6 Pot Caliper D2 Brake Disc and Bell Assembly D2 6 356mm Pot Brake Kit D2 Caliper Seals D2 Caliper Bridge

VXRacing AP 4 Pot Brake Kit - Astra, Zafira and Corsa

Full Size Image - Click Here
Astra VXR AP 4 Pot Brake Kit
Click Thumbnail for Larger Image
Full Size Image - Click Here
Blue or Red Callipers Available
Click Thumbnail for Larger Image
This Brake Kit comprises of a pair of 2 piece 345mm 6 grooved discs with alloy bells, AP Racing 4 pot callipers with road seals, braided front brake hoses, brake pads and AP brake fluid.
The callipers are available in either Red or Blue with the both the VXRacing and AP Racing logos.
 £2074.50 Supply Only Buy Now Click Here!
This set up will fit Astra and Zafira VXR, and all Astra G/Zafira A and Astra H/Zafira B models. Requires 18" wheels.

An AP 4 pot kit is also available to suit Corsa D similar to the above, but designed to fit under factory 17" wheels on Corsa VXR £1998.00

Available Pad Compounds: EBC Yellow and Blue Ceramic, Mintex M1144, Pagid RS29, Original Spec Pads.
Replacement Brake Discs and fitting kits available. Buy Now Click Here!

278mm Rear Brake Upgrade - Astra and Zafira

278mm Rear Disc Upgrade Our 278mm rear brake upgrade kit includes a pair of rear caliper backplate/mounting brackets, a pair of 278mm rear discs and a set of OE rear pads. We recommend that this upgrade is carried out only where the front brakes have already been upgraded to a minimum of 322mm, to prevent over braking the rear.

Suitable for all 5 stud Astra H (Not VXR) and all 5 stud Zafira B (Not VXR or later 2.0 Turbo LER models VIN: 62000001/6G000001 on)

Vauxhall Retail Price £397.00 Our Price - £270.95 inc VAT

8 Groove Discs £76.95 extra. Red and Yellow ceramic pad upgrades available. Image shows OE Lucas pad set
Also Available: Kit For all 5 stud Astra G and Zafira A - £668.95 includes rear VXR calipers and brackets (not shown in image above)

292mm 5 Stud Rear Brake Kit - Astra and Zafira

In response to some serious fast road and track day warriors, we teamed up with our friend Dave Peace to develop an Astra VXR 292mm Vented rear brake kit to compliment the large front brake kits already on the market.

With large front brakes the car nose dives and tries to grind the front splitter into the tarmac, whilst the rear of the car can become very light. The larger diameter rear discs even this out making the car flatter under braking.

For those people who track their car hard, the vented rear discs will be a big bonus as the factory ESP system works the rear brakes very hard during hard & high speed cornering, as the ESP remains partially active even when switched off via the sport button.

This kit has been developed and tested on both Dave’s and our own cars and is fitted to our own Astra Sprint, and has been tested on track and at the legendary Nürburgring Nordschleife. We have also got a kit running on an Astra VXR/OPC Race car in South Africa where overheating was a big issue!!

Here’s what you get.....

2 x 292mm Vented Rear Discs
2 x Caliper Carriers
2 x Caliper Bodies
2 x Billet CNC Machined Backplates/Caliper Mounting Brackets
1 x Pad Set
2 x Anti Rattle Springs
4 x Caliper Mounting Bolts
4 x Stainless Steel Braided Hoses

Whilst this kit has been designed for Astra VXR, it will fit Astra G and H and Zafira A and B, providing suitable front brake upgrades have been carried out.

Price - £795 8G Discs - £76.95 extra with kit.

292mm Brake Kit

Fitted - Plain Disc

Fitted - 8G Disc

345mm 5 Stud Brake Kit - Vectra C/Signum

345mm Brake Upgrade Full Size Image - Click Here Courtenay Sport's 345mm Brake upgrade kit suitable for Vectra C and Signum. Huge increase in stopping power and fits under 18" alloy wheels. This upgrade kit includes a pair of 345mm vented discs, OE VXR pads with calipers and brackets finished in VXR blue.

345mm Brake Kit Vauxhall Retail £1135 Our Price - £805.95 inc VAT
16 Groove Discs £76.95 extra. Pad upgrades also available.

K Sport 8 Pot 356mm Brake Kit - Vectra C

K Sport 356mm 8 Pot Brake Kit This kit comprises of a pair of 2 piece 356mm x 32mm 8 grooved discs with alloy bells, Lighweight Alloy K Sport 8 pot calipers, brackets and stainless steel braided front brake hoses. The calipers are machined from aircraft quality billet with machined grooves to protect the bridge link pipes and have alluminium pistons, high temp seals and stainless steel brake pad wear plates.

The calipers are finished in Black. Pads can be specified to suit requirements.
Yellow ceramic pads make good fast road and track day pads, whilst Blue ceramic pads are available for track/race use only as they are not road legal. Pagid RS29, Ferodo DS2500 pads and EBC Red Ceramic are also available for this 8 pot kit.

This brake kit will fit under 18" Team Dynamics Pro Race 1.2 Wheels ET40mm, Standard 18" Snowflake Wheels and the optional 19" VXR Wheel (clearance is close on the 19" wheel and a 3mm - 5mm spacer is suggested).

Lit Price £999.00 :: Fitting available in our workshop. Requires 18" wheels with correct offset for clearance.

Replacement Pad Sets available from £122.50

VXRacing AP 362mm 6 pot Brake Kit - Vectra C

VXRacing 6 pot Brake Upgrade Full Size Image - Click Here VXRacing AP 6 pot Brake Upgrade for Vectra VXR.

This Brake Kit comprises of a pair of 2 piece 362mm 12 grooved discs with alloy bells, AP Racing 6 pot callipers with road seals, braided front brake hoses, brake pads and AP brake fluid with both the VXRacing and AP Racing logos.

£POA

292mm 5 Stud Rear Brake Kit - Vectra C/Signum

292mm rear brake upgrade kit suitable for Vectra C and Signum. Match increased stopping power at the front with additional stopping power at the rear. This upgrade kit includes a pair of 292mm vented discs, OE pads with calipers and brackets finished in VXR blue.

292mm Rear Brake Kit Our Price - £509.95 inc VAT
8 Groove Discs £76.98 extra. Pad upgrades also available.

Courtenay Sport Braided Brake Hoses

Brake Line Kit Astra/Zafira VXR Front
Astra/Zafira VXR Front
Brake Line Kit - Astra/Zafira Rear
Astra G/Zafira Rear 4 Line Kit
Full Brake Line Kit VX220
VX220/Speedster Brake Line Kit
Brake Line Kit Astra G/Zafira A Front
Astra G/Zafira A Front
Courtenay Sport Braided Brake Hose Kits. Stainless steel braided hoses, plastic coated to resist dirt, rain, salt and fitted with high quality stainless steel unions. Improves pedal feel, eliminates ballooning caused by rubber OE hoses, improves braking performance. Stainless unions are more resistant to corrosion - some similar kits use zinc coated unions which are not as hard wearing and more prone to corrosion. Kits contain new banjo bolts, washers and rubber supports where needed. Astra/Zafira rear brake line kits also include  the required joiner pipe. Available for VX220, Astra VXR, Zafira VXR, Corsa VXR, Astra G, Zafira A and Vectra B. Other models to be added. Prices from £38.40 Buy Now Click Here!

Brake Ducts for Extra Cooling

Brake Ducts designed to direct cold air at the brake discs for additional brake cooling. Simply clip onto the lower arms. Suitable for Astra G, Astra H, Zafira A, Zafira B, Vectra B, Cavalier and Calibra.

Price £19.95 per pair. Buy Now Click Here!
Brake Cooling Ducts

Brake Ducts Shown Fitted to Astra VXR

Full Size Image - Click Here
Brake Duct Fitted
Full Size Image - Click Here
Brake Duct Fitted.

Racing & DOT 5.1 Brake Fluid

Delphi Lockheed Racing Brake Fluid has been formulated for racing applications where braking systems operate at high temperatures. It guards against vapour lock and maintains its viscosity and lubricity at extreme temperatures. This fluid conforms to and exceeds the current specification for DOT4 and has a typical dry boiling point of 310 o C (590 o F), which is higher than DOT5.1 fluids which typically have a dry boiling point of 260 o C.

£12.60 per 500ml. Buy Now Click Here!

DOT 5.1 Brake Fluid, ideal for fast road use as it has a typical dry boiling point of in excess of 260 o C,  which is higher than DOT4 fluids which are usually supplied from the factory.

£12.60 per litre. Buy Now Click Here!

Brake Fluid - Some Facts

Due to the fact that a brake system is not perfectly sealed moisture can be absorbed by the fluid. This in effect reduces the boiling point of the fluid and can reduce the efficiency of the brake system. Another factor of reduced braking efficiency is fluid that has got too hot and boiled, turning it into gas which leads to a 'spongy' feeling.

Brake fluids are classified to defined specifications: DOT3, DOT4, DOT5, DOT 5.1 These specifications have two reference tests:
Dry Boiling Point, the boiling point of fresh fluid
Wet Boiling Point, the boiling point once the fluid has absorbed water, representing fluid that has been in use in a vehicle.

There are two main types of brake fluid:

DOT3, DOT4, DOT 5.1 which are glycol based (Poly Alkylene Glycol - PAG) & DOT 5 which is synthetic based.
The two types of fluid are not compatible and must not be mixed in a braking system.
Minimum Dry and Wet Boiling point specifications:
Minimum Boiling Point oC DOT 3 (PAG) DOT 4 (PAG) DOT 5 (silicone) DOT 5.1 (PAG) Racing Brake Fluids
Dry 205 oC 230 oC 260 oC 260 oC 300 oC
Wet 140 oC 155 oC 185 oC 185 oC 195 oC

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Courtenay Sport Vauxhall Tuning
Courtenay Sport
 Vauxhall Tuning

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