E46 BMW M3 Brembo / Rally-Road BBK Install - Dorkiphus.net
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Old 06-26-2017, 05:02 PM
HughA44s HughA44s is offline
 
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Default E46 BMW M3 Brembo / Rally-Road BBK Install

(Flame Suit On – Check) I do not like the single-pot floating brake calipers used on these cars for track driving. Yes, I know, some people use them (with track pads and SRF), and I know some series require them, and I know people get by with them but I also know people that have had major issues ( Flying off turn 1 at SP and hitting the wall, etc) with them – including me (I just almost flew off but did not hit a wall). To that end, I decided to go the following route as mentioned in the title. So ……

First Step: Get some 996 / Caymen S Calipers – I got mine from John T’s deer strike 996. This seemed like a good approach because in theory, they had the fluid changed frequently ( was a Tech Inspector and is an Instructor) and I got a complete set from the same car.

Then,send them to Rally Road for a bit of machining – 5.5mm off the mounting pads to be exact.

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On go the brackets – these are beautiful. Note the mounting studs so that you do not have to Time-Sert the suspension parts after you pull the threads out upon removal (you know who you are). I did have a slight issue with the stock mounting bolts. The shoulder on the bolts bottomed out on the threaded bracket before I could get to the correct torque. A thick washer between the head of the bolt and the suspension mount holes fixed this. I need to find a better set of bolts and remove the washer but this is fine for now. The threads on the RR brackets come right to the edge where-as the stock brakes have a slight reset for the bolt shoulder to go into.

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Next, on go the rotors. These are 345mm by 28mm rotors used on a ZCP/CSL. In this case, I went with the ECS versions of these rotors. These look to be OEM 2-piece rotors, modified and drilled. I could have gone without the drilling but these are heat-treated, have replaceable friction surfaces, and are pretty. We will see how these hold up. I inserted a screw-driver to check which way the internal vanes were going. It turns out PFC also makes a set of 2-piece rotors that should work. Clearly, when these brackets were designed, the designers put as much meat on them as possible at the point where they are threaded and bolted.

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WOOPs – First Issue. The bottom, inside pins on the brake calipers were making contact with the rotor after the caliper was installed. None of the threads I saw mentioned this, so I filed these down a bit, approximately 1.5mm with a hand file to get clearance. I may need to file a bit more – we will see. Others options to considered, if it is a problem, is take the rotors apart and have the faces machined 1mm.

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The calipers go on easy now.

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The rears were the same but required no filing but did need the dust shield trimmed.

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Here, Kitty completes his inspection of the custom DOT approved brake lines (also obtained from RR) and indicated his “like” by lounging next to them.

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For some stupid reason, I forgot to take some pics of the completed project without the wheels on but oh well. I used 10mm spacers on the front but 12.5mm spacers would be better for a bit more clearance – will change if there is an issue. Please note the beautiful wheels. Wheel Doctors did these in satin graphite. There is not a lot of info on this setup in terms of pads but I have decided on DTC-60 all around as a starting point for track usage.

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  #2  
Old 06-26-2017, 05:18 PM
HughA44s HughA44s is offline
 
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WOOPS how dump of me. This car is hard to take pics of because it reflects the surroundings.

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Old 06-26-2017, 05:53 PM
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Love it. Gotta ask, because I've looked at big brake kits for M3 and they are $$$$$$ - what'd this run you?

Main thing I'd be concerned about is bias. Not sure how the 996 calipers compare to the stock single pots piston-area-wise, but it seems like the 996 calipers would be a lot more front biased.
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Old 06-26-2017, 06:31 PM
HughA44s HughA44s is offline
 
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800 Calipers
500 brackets and hoses
750 disks
Pads of your choice

As far as front to back bias goes, hmmmm. There is a bias formula/model available on m3forums which allows you to calculate it (I think) but I have not done it. This looks to be very similar to the wildwood kits I have on my other car. Also, I know it will not confuse the BMW ABS. In the end, I plan on using pads to tune if it is an issue. The reports I have seen do not indicate this is a problem. For reference, I looked at the "fast-lap" time threads over there and this pad setup seems to be in line. OG also mentioned this is a viable approach.
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Old 06-26-2017, 06:33 PM
HughA44s HughA44s is offline
 
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I was thinking of measuring the diameters of the pistons and determining their ratios and comparing that to stock and the wildwood kit I have and love.
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Old 06-27-2017, 02:59 PM
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Nice write up! BM-orsche!
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Old 06-27-2017, 03:42 PM
HughA44s HughA44s is offline
 
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Thanks NOTTON. Now the real question is S or R? Also "Race Car" or "GTB1 Car" or "GTSX Car" Come on - this is the BMW Thread and no one ever comes over here. I promise I will not tell.
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Old 06-27-2017, 09:29 PM
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Quote:
Originally Posted by HughA44s View Post
Thanks NOTTON. Now the real question is S or R? Also "Race Car" or "GTB1 Car" or "GTSX Car" Come on - this is the BMW Thread and no one ever comes over here. I promise I will not tell.
"BM-LUMP", "BM-POS"??

Remember theses fro a couple of months ago?
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I like your rotors better. Your calipers need some paint!
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Old 06-27-2017, 09:46 PM
HughA44s HughA44s is offline
 
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TR - Agree with the paint. I talked to a Dorki about getting them powder coated and he recommended against that for reasons of heat retention. I will do the paint next time I take the off - I am thinking a nice Cobalt Blue. Yes I remember those from Tech. I do like his wheels.
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Old 06-28-2017, 09:54 AM
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I've also been thinking of doing the 996 brakes since I don't know if I want to pony up for the PFC BBK. Could you elaborate on the issues with the stock calipers you are referring to that would cause runoffs?
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