DefSport 12.2" Wilwood Superlite Front Brake Kit GB Part 2!!!

[Def]

Install Instructions




Final shipped prices are $400 for 5 lug, $420 for 4 lug.




The initial signup process will probably run for 2-3 weeks before payment is required. Delivery to me is estimated at 4-6 weeks after that (depending on GB volume), then I will ship out from there. Material ordering happens as soon as we get enough money to cover it (and a 9' long piece of 8" round aluminum isn't cheap!), so that's the reason for the compressed payment timeframe.

ENGINEERING DETAILS

The design goal for the hat was a semi-floating design(the best possible with the Wilwood rotors - they cannot be fully floating in the space available). With this in mind, I have allowed for a radial slot where the rotor mounts to the hat that is equal to the thermal expansion between the two materials(iron and aluminum) at a plus or minus 1000 deg F delta. Therefore, the rotor and hat should be able to freely expand and contract at their different material-defined rates with minimal binding. This should keep the rotor from wanting to grow into a "cone" shape that the Wilwood hats force due to being solidly held on one side(threaded into the hats). The hat design keeps the cross sectional area high at all stress paths, yet uses a minimal amount of material. The total weight of the hat is 1.53 lbs, and the rotational inertia is about 40% less than the typical "flat cup" Wilwood rotor hat.

The hardware kit uses mechanically deformed mil-spec lock nuts, as well as spring washers to maintain tension.

The caliper bracket is made from 2024-T3 aluminum alloy, which has exceptional fatigue resistance as well as hardness and yield strength approaching that of mild steels and surpassing that of most grades of cast iron. This is a true structural "aircraft" alloy of aluminum, and is exactly what most bulkheads are made of in modern fighter aircraft. The large cross sectional section enables a very stiff and strong bracket, and the usage of aluminum keeps the weight below 0.3 lbs.

...and don't worry, it's all been scienced:





Don't worry about the distorted looking bracket - CATIA magnifies things around 1000x to make displacement visible. This FEA run was a rough assumption of Superman-style S chassis performance and its effect on the bracket. The loading assumption was all braking on the front wheels with 25" tires and total braking decelleration of a 3000 lb S-chassis at 1.5 G's. That would put actual real world braking in the ~1.8-2G range for this loading case. Max loads are around 8 ksi, which is a reasonable level for long term fatigue life without unncessary bulk. So you should be able to pull ~2 G's under braking about 10-100 million times without worry. I just want to actually see one of you guys pull that much braking force somewhere.

Total displacement at the lug mounting holes is about 0.0015" at this braking, so very low. The stock spindle is going to be deflecting more than that I suspect.

The FEA analysis did bring about a few design minor design changes, so they're not just pretty pictures.

Pushing it beyond the S-chassis aftermarket "well it works I guess" phase, kids!


KIT INFORMATION

Prototype kit shown without anodizing.



Brackets are made from 2024-T3 "aircraft aluminum" - this is the same stuff they use to make bulkheads and brackets in aircraft due to its high strength and fatigue resistance. Hats are 6061-T6 to keep the cost reasonable.



You know it, son!



The rotors will be held to the hat with Grade 8 bolts, high temperature spring washers(belleville washers), and military spec "jet nuts." These are high temperature, vibration resistant nuts used on military aircraft. They're also the same nuts PFC uses on all their brake kits.



A picture of the hard anodizing. Oh what's that? It matches the Mil-Spec hard anodize of the D38999 electrical connector on the back of Stack dashes? You know me, I like to color coordinate the :ballerness:.



Back side



If you want to add Speedbleeders to your Wilwood FSL calipers - here's the Russell p/n(it/s a 1/4-28 bleeder). So now you know, and knowing is half the battle.


"So how's it all look Def?" you ask - budget baller of course!




But does it all fit well? You bet your ugly ass it does!



Pistons are fully retracted on both sides. As you can see - fitment is perfect.


Bracket looks budget baller:





GB run will have both the hat and bracket hard anodized a gunmetal grey.


Pricing for (2) hats and (2) brackets is $345, (1) mil-spec rotor hardware kit is $40. Shipping is an extra $15. The final kit pricing(before shipping) of $385 included EVERYTHING you need to bolt the below-linked calipers and rotors to your car. It is a bolt-on kit that anybody can install with a few hand tools. You source the calipers, rotors, lines, and pads yourself (linked below), since they are readily available off the shelf.

Parts list and price breakdown vs. the $1000 Wilwood kit for S13/S14:

Def's kit:

Hat + brackets = $345
Rotor Hardware Kit = $40 <---Hat + Bracket + Hardware kit is what the GB is for!
WIL-120-11133 FSL Caliper (x2) = $150x2 = $300
WIL-160-2894 12.2x1.25" rotor (R) = $42
WIL-160-2895 12.2x1.25" rotor (L) = $42
Wilwood BP-10 pads(although I recommend Hawks) = $60


Total = $829 (comparing to what Wilwood kit comes with)

Wilwood's kit street price is over $200 more for a 12.9x1.1" rotor kit with the same calipers. Wilwood leaves you also needing to purchase the lines, and for that I recommend the WIL-220-9199 ($60)brake line kit if it's in stock.

You can alternatively build your own lines with a premade -3 AN teflon line (from Earl's, Fragola etc.), and a 10mm x 1mm Inv Flare to -3 adapter for the chassis line, and a -3 AN to 1/8"-27 NPT fitting for each caliper (note you will need 2 chassis adapters, 2 for the caliper, and 2 lines - 1 set for each side).

If you have over 400 rwhp and are running these kits on track, I suggest the heavier duty rotor rings that have 48 curved vanes, Wilwood P/N 160-5845, 160-5846. This kit should handle even the highest HP S/Z chassis on track since these are the same brakes you'll find on many 800+ HP circle track cars. Mine run icy cool (<300 deg F) coming off track with over 300 rwhp. Pad life is exceptional with this kit. I recently got 16 track days out of a set of front pads and still had enough for an extra day or two.

Advantages of this kit

1. Weight savings - Save approximately 18-20 lbs over a 30mm Z32 front setup, about 25-27 lbs over an EVO/STi Brembo setup
2. Low running costs - $42 rotors, and pads that are ~40% thicker and about 40-50% cheaper than Z32 pads will have the kit paying for itself if you track your car. Let the huge economies of scale of the circle track guys work for you!
3. Race bred caliper design - lighter and most likely stiffer than a Z32 caliper - the Forged Superlite is good stuff.
4. More brake cooling up front - the cooling channel in these wider rotors and directional vanes pump a huge amount more air than Z32 front brakes. This should keep brake temps down all things equal.

Alternative brake pads I recommend(LPIRacing does free shipping for any order over $100 - definitely a bargain! I get all my pads from these guys!):

-Hawk HT-10 for track usage - low cost, more difficult to bed
-Hawk HPS for street usage
-Hawk DTC-60 for track usage - easy bedding

I'll be taking orders for a few weeks then start production. If you want the rotor hats and brackets, I highly suggest jumping in on the GB. I do not expect to have significant extras.

Parts Price = $345+40 = $385 for 5x114.3mm bolt pattern hats

Add $20 for 4x114.3mm hats (becomes a nightmare to keep track of a few custom parts in a sea of other ones, but it can be done)

Shipping is $15 in the lower 48 states. Contact me for overseas shipping quotes.

Final shipped prices are $400 for 5 lug, $420 for 4 lug.

List:
*No "4 lug" notation means you are signed up for 5 lug(5x114.3) hats

1. jbennett58
2. 2_Liter_Turbo
3. KNerd *4 lug*
4. Bubba
5. Own3r
6. blackej7 *4 lug*
7. WorkinprogressK *4 lug*
8. Klys
9. galantx
10. BAMF_S14
11. onosqv
12. 95silvia14
13. SOneThreeCoupe
14. Jrocks13
15. A.Brent
16. jham4x4
17. speed_demon
18. konjiki7
19. twistedsymphony
20.

Total: 19

[jbennett58]

I will take one set

[nismofly]

Originally Posted by Def

Your nuts are hairy

Sorry I couldn't help myself

[Def]

I blame the brains behind DefSport:

[2_Liter_Turbo]

Put me down for a set! I'll have the money within 10 days (waiting for paycheck ). What are the payment details (paypal I'm assuming)?

[Def]

You guys sure are making me work for this list...

[Def]

Copy and add yourself to the list if interested:

1. jbennett58
2. 2_Liter_Turbo
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Total: 2



And yes, payment will be through Paypal.

[KNerd]

1. jbennett58
2. 2_Liter_Turbo
3. KNerd *4 lug*
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Total: 3

[cdlong]

Do you have the dimensions necessary for wheel clearance? I'm ordering a set of Custom wheels in a few weeks and want to make sure these will fit. (not ready to order a set right now)

[0wn3r]

Passenger side rotor is straight vane and driver's side is directional/curved?

Put me down for a set.