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Astra VXR Tuning

Courtenay 16G Brake Discs

Courtenay 16 Groove 322mm Brake discs for greater stopping ability due to increased surface area. The grooves also help to keep the pads clean and disperse heat, brake dust and gasses away from the disc surface, a common cause of brake fade. They also draw cooling air across the disc surface and between the pad and disc to keep components cooler.

Front 16G Discs - £222 per pair

Rear 8G Discs - £156 per pair
Full Size Image - Click Here
16G disc shown fitted.

EBC Uprated Turbo Grooved Discs

EBC's wide groove discs are designed to pull cool air under the pad surface and between the disc to help both pad and disc cooling. EBC's "Blind Drilled" dimples help break down surface gasses but do not promote cracking, which has been known to occur, especially on fast road and track day use with conventional "Through Drilled" discs.

As well as aiding cooling, the grooves in the disc surface also allow dirt, dust, gasses, debris and grit to escape from between the disc and pad surface, especially under heavy braking. The grooves and dimples also keep the pad surface de-glazed throughout its useful life.

EBC sport discs are also gold anodised to help prevent from corrosion in

areas which are not swept by the pad to help them stay looking better for longer. Optimum brake performance is reached once the zinc coating is removed from the pad contact area, which when used with EBC ceramic pads and the special brake in coating on their surface will often occur in as little as 50 miles.

As with our own 16G discs it is normal to expect a little additional brake noise from these discs during normal use.

EBC Discs Per Pair Front - £153.50  Rear - £119.00

EBC USR Slotted Discs Also Available

Brembo OE Specification Plain Discs

We can supply OE Spec Brembo Plain discs, ideal as a direct replacement set up for standard.
Front 322mm - £138.00 Rear 278mm - £69.00 Priced per pair

EBC Performance Brake Pads from Courtenay Sport.

After extensive product testing and in depth discussion with the manufacturers, Courtenay Sport are pleased to supply a range of uprated fast road brake pads from EBC, for the most popular applications to accompany our range of performance discs and the EBC grooved and dimpled discs.

In far too many instances we have seen green stuff pads incorrectly specified in high powered cars e.g. Astra Turbo, as an upgrade pad but which are evidently not up to the job of stopping a 200 + bhp car. These pads work as an acceptable replacement on lower powered or light cars but as a fast road uprated pad they are not a good choice for the vast majority of applications, which is why we choose not to supply this pad. For this reason you will not find us recommending them on or fitting them to inappropriate applications.
Red Ceramic Logo Having looked at the various applications involved, it has become clear to us from in-house testing that red ceramic and yellow ceramic pads and good choices for fast road and track day use and offer a big improvement in brake performance when used under extreme application, yet still offer a good pedal feel when cold. Red ceramic pads are an ideal fast road pad which comfortably operate at temperatures around 550oC, and in tests by Lotus have remained stable up to a pad temperature of 700oC, yet for the fast road driver these
temperatures will never be reached on the road.
For the more demanding driver,and those drivers who have a more track day biased use for their vehicle the yellow ceramic pads will offer and even better performance at higher temperatures. Offering good bite from cold, the yellow ceramic pads offer better stopping ability and operate at greater temperature ranges, offering a big improvement over standard items, especially when matched to uprated discs. Yellow Ceramic Logo
Both Red and Yellow ceramic pads come with a brake in coating to the pad surface to help faster bedding in of brake components. This mild abrasive red coloured coating lightly scrubs the brake disc after new pad installation allowing optimum braking to be achieved faster. This coating is especially useful when fitted to EBC zinc coated discs, as the brake in coating quickly and safely removes the zinc coating from the disc surface.

Yellow Ceramic Pads - Nominal friction coefficient 0.5 Mu when cold. At 550 degrees C, 0.31 Mu and at 800 degrees C, 0.21 Mu

Red ceramic and Yellow ceramic pads for fast road and trackday use are available for most models.

ALL Red and Yellow Ceramic Pads that we supply are road legal with R90 approval.

We can also source Blue NDX pads for race or track day use (may not be road legal)

Brake pad Operating Temps - Click to Enlarge.
Red and Yellow Ceramic pads available for Front and Rear.

Red Ceramic Pads - Front £89.95 / Rear £53.65
Yellow Ceramic Pads - Front £95.00 / Rear £69.00
Pagid S Pads. Pagid S Sportspads have been specifically designed for high performance brake system usage on public roads, but it is no secret that their origin is the race track and where they truly belong.
High friction, low fade characteristics and low pad wear over a wide temperature range make these pads ideal for use in club racing, track days and on public roads.

£154.20 per set Buy Now Click Here!

Uprated Brake Pads - Mintex

We can also supply Mintex M1144 pads for fast road use for Astra VXR. A well known pad and used and recommended by many people. Available for Front and Rear. Available for Factory Calipers with 322mm Discs and also AP VXRacing Calipers with 343mm Discs
M1144 Pads for Factory Calipers with 322mm Discs - Front £91.95 / Rear £81.65. AP/VXRacing - £110.00

Brembo Sport Brake Pads

Brembo Logo
Designed for the road, developed on the track.

The new sport pad range is the latest pedigree to come out of the Brembo high performance stable. Tested to the highest levels on the track with decelerations from 270 kph (168mph) the HP2000 material is capable of operating in the most demanding conditions.

With excellent cold performance & bite, high resistance to fade, frictional stability throughout all operating conditions, reduced pad & disc wear and low dust levels, the all new HP2000 friction material offers significant advantages over its rivals. Designed to be a direct replacement for the Original Equipment (OE) pads the Brembo sport pad comes with the exact same specification as the OE pad including (where applicable): fitted wear leads, slots for separate wear leads and anti-rattle clips with the added benefit of anti-noise shims on every pad.

Combine all of this with competitive pricing and UNECE R90 approval across the full range (making them street legal) and you get a true high performance brake pad fit for the road.
Brembo Sport Pads Designed and tested for predominantly performance-oriented street use, Brembo Sport brake pads represent the first upgrade level for any braking system.

Designed and tested for predominantly performance-oriented street use, Brembo Sport brake pads represent the first upgrade level for any braking system. These products have been created for drivers with sporty ambitions and, more generally, for anyone who wants to maximise the potential of their car.
These pads boast levels of manufacturing quality and advanced materials that only Brembo can offer. They offer outstanding performance even without warming up and at low speeds, thanks to a specific friction material that ensures constant friction at all temperature ranges. In addition to enhanced performance, this material also ensures outstanding quietness and reduced disc and pad wear.
Excellent performance in all situations.

Brembo Sport brake pads also offer exceptional brake pedal precision, for total control of the braking force. While they work best at temperatures between 200 and 300 °C, they can withstand much higher temperatures - up to 600 °C - and are designed to deliver both superlative performance and satisfactory levels of comfort. These are therefore the ideal brake pads for drivers who demand the best from their brakes, even during everyday use.
Brembo Sport Pads
Available for Astra H VXR with AP VXRacing 343mm Discs. Buy Now Click Here!

Front Pad Set (AP) from £150.00 :: :: Rear Pad Set (Lucas) £87.95

OE Specification Pads

We can supply OE and OE Spec pads. Front - OE (Genuine) £72.00 Ferodo OE Spec £54.00
Rear - Ferodo OE Spec £36.00 Pads priced per set

Astra VXR Braided Front and Rear Brake Hose Kit

Braided Brake Hoses - Front

This hose kit consists of a front pair of uprated braided brake hoses, with new unions at each end and new banjo bolts and washers. The braided hoses are sleeved with clear plastic to further protect them from the rigours of salt, dirt and water during everyday use, and have a rubber mounting piece to locate them. Offering improved brake feel under extreme braking, as they will not balloon like 'OE' hoses can, they are especially suited for fast road and track day use.

Braided Brake Hoses Front - £57.00 per pair with new banjo bolts and washers Buy Now Click Here!

Rear Brake Line Kit - 4 braided hoses with brake line joiners - £69.80 Buy Now Click Here!

K Sport 8 Pot 330mm and 356mm Brake Kit

K Sport 356mm 8 Pot Brake Kit This kit comprises of a pair of 2 piece 330mm or 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. 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.
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 which we can supply if required).

356mm Kit Price £978.00 Buy Now Click Here! :: Fitting available in our workshop. Requires 18" wheels with suitable offset.

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 330/356mm £359.00 per pair Buy Now Click Here!

D2 6 Pot 330mm and 356mm Brake Kit

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. Buy Now Click Here!

Replacement Discs 330/356mm £359.00 per pair Buy Now Click Here!
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

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, as fitted to our own Astra VXR, 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.
Blue Kit £2074.50 Red Kit - Enquire :: Fitting available in our workshop. Requires 18" wheels.
Replacement M1144 Pad Set £110.00 - Buy Now Click Here!

Available Pad Compounds: EBC Yellow and Blue Ceramic, Brembo Sport HP2000, Mintex M1144, Pagid RS29, Original Spec Pads. Buy Now Click Here!
Replacement Brake Discs £545 per pair Fitting kits available. Buy Now Click Here!

292mm Rear Brake Disc Upgrade

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 is what is included:

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 OE 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.

Kit Price - £795.00 with plain discs. 8 Groove Discs - £76.95 extra with kit.

Replacement Discs :: 8G Brembo Discs £180.00 Plain Discs £99.00


292mm Brake Kit

Fitted - Plain Disc

Fitted - 8G Disc

Brake Cooling Ducts

Brake Cooling Ducts Brake ducts designed to direct additional air flow towards the brake disc to aid brake cooling. Simply clips to the lower arm. Simple, inexpensive, functional and they work.

£19.95 per pair. Buy Now Click Here!

And Fitted


Brake Duct Fitted - Front View
Full Size Image - Click Here
Brake Duct Fitted - Rear View

Fog Light Delete Brake Duct Kit

Our foglight delete brake duct kit, as used on the Astra Sprint Editions, is designed to get additional cold air directly to the disc and caliper assembly. Once the fog lights are removed, which gives the added advantage of weight saving a consideration for track use, the kit is installed and include semi rigid convoluted ducting with plastic finishers and 3 trumpets. 2 are bonded into the OE foglight surrounds (which can be seen painted in black flexible anti stone chip paint in our image) and one is bonded into the plastic bottom pulley cover which makes for easy removal for getting access into the cambelt area and oil filter. The ducting is then fitted as required between the fog light surrounds and the brakes. They will direct additional air flow towards the brake disc and caliper to aid brake cooling.

£19.95 per pair Includes ducting and finishers. Buy Now Click Here!
Brake Cooling Ducts

Enlarged Fog Light Delete Brake Cooling Kit

Our enlarged foglight delete brake cooling kit is designed around the same principle as our original kit to get additional cold air directly to the disc and caliper assembly, only it is larger. Again the fog lights are removed to allow the ducts and ducting to be fitted, saving weight. The kit includes 1m of convoluted ducting, 4 plastic trumpets/ducts, a pair of new foglight surrounds (which can be seen painted in black flexible anti stone chip paint in our image), cable ties and fitting info. Once fitted this directs additional air flow towards the brake disc and caliper to aid brake cooling.

These are especially useful for cars undertaking track days.

£59.95 per pair includes ducts, ducting and a pair of new chrome surrounds. Buy Now Click Here!
Brake Cooling Ducts

Racing 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

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 sepcifications 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
Slicone Brake Fluid (DOT5)
DOT5 was introduced to give higher temperature performance over DOT4. It will also not damage paintwork or absord moisture. However it is a poor lubricant and does not lubricate ABS pumps as well as PAG fluids and as it does not absorb water, any water in the system will remain as water droplets which can pool and cause corrosion or vaporise when heated under heavy braking causing severe braking efficiency loss.

PAG Brake Fluids (DOT3, 4 & 5.1)
DOT4 is the current mainstream brake fluid. DOT 5.1 has a higher specification and is intended for fast road and occasional track day use.
Racing brake fluid is usually designated DOT4 however it's performance exceeds that of DOT 5.1 fluid as shown in the above table.

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