May 9, 2011
ooooo i do like
thats nice man, thats very nice man!
I'm going to strip them this week and do a guide. Going to get new bleed nipples, piston seals and the like. I'll get the powder coated mail box red before putting them back together.
Undecided on what decal to put on the calipers though, Brembo, Porsche, Audi, or another
I'd put: 'HOT!'
Because they will be quite a lot of the time.
HI could have this on them
a perfect example of porsche brakes
Right I've decided to go with dark blue Brembo stickers to keep with the dark blue and red theme on my car.
Should've stayed with 'Porsche' as a nod to the great grandaddy of S/RS cars, RS2.
Anyway, your car is going to be a very well sorted KO4'd car - i'm looking forward to seeing how it turns out!
Good luck with everything.
Just found somewhere with 25mm PCD adapters in stock so I've ordered them up and should have my S4 wheels on this week.
Also fitting B5 TIP and S3daves adjustable tie bars this week too then it's off for a 4 wheel alignment.
Loads of work going on here lately then Neil!
can't wait to see this at the Ring in september, sounds like it's going to be a proper weapon!
Must have a ride :busted_cop:
I can see the light at the end of the tunnel now so I'm trying to get the thing finished before the Ring. Just hope it comes back in 1 piece.
Looking good mate, I might be heading up to the ring and meeting you guys just waiting to see if my mate in his s2000 can get the time off work, then were going to road trip it from Spain lol
I started stripping the calipers tonight but hit a dead end at getting the pistons out. Does anyone know if it can be done without and air tool to push them out? I tried using a bike pump as heard that it would do the job but I cant get a good enough seal to push out the pistons.
Might be wring but I think you have to rotate then as you apply pressure.
I hate iPhones sorry for the bad spelling.
Nah mate otherwise the pistons wouldn't come out when you pressed the pedal
I've read a few guides and they use a tool so I might try and get one. I'll probably strip and refurb my standard ones when i have these brembos o and then sell them so it'll be worth buying the tool.
How to Rebuild a Brembo Caliper - TechWiki
That's a 1 piston brembo caliper and is completely different to the 4 pot Porsche calipers. I'll post up the link to the guide I have tomorrow as it's on my work PC.
Here's the guide:
Brake Caliper Rebuild - Do-It-Yourself Instructions For Racers - Circle Track Magazine
Front PCD adapters turned up today. Rears should be here tomorrow.
Started on my calipers tonight:
Removed the fluid inlet first with a 10mm spanner:
I then removed the safety clip in the pin that holds in the pads and bashed out the pin:
With the pin and squeal plate out the way I could remove the pads:
The 4 nobles you can see here need to be filed down a mm each one as the boxster discs are 1mm thinner than the S3 standard discs. I'll do this last:
I then gave the surface a quick clean:
Bleed niples off with 11mm spanner to drain any fluid in the caliper:
Finally, used a foot pump to get the pistons out. My mate was a bit hasty and we didn't get a piece of wood in the middle so that all 4 pistons came out together (muppet!), so only 2 came out, I'll have to find another way to get the other 2 out before I dremmel the 4 nobbles and send them off for a powder coating:
Car is ready for collection tonight. Just needs a road test by 4Rings to ensure all is ok before I collect. Loads of work done to it:
- New turbo
- New CV boot
- New front ARB
- 3" downpipe and de-cat
Late night mechanics is also booked in for tomorrow night to fit the following:
- Badger 5 TIP
- S3dave's adjustable Tie Bars
- Poweflex tie arm bushes
S4 wheels going on Sunday then off for 4 wheel alignment next week. It's all coming together nicely
I bet it's going to be awesome after that lot. I'm keen to see what difference the B5 TIP makes to mine as it's standard otherwise really.
I am jealous you can perform late night mechanics. I have no where to do it really
I think I'm going to aim for something like yours, a "sorted" K04 car as you put it. Just bought a Peloquin diff for the rear. Handling first I think
It should feel brand new when I pick it up. Still got FMIC and then probably go Revo Stage 2 in the next month or 2. Then it's time to tackle the paint work.
Lots of pics to follow tomorrow night
I dont know much about diffs what difference with the Peloquin diff make?
Excellent. Let me know how the B5 TIP goes!
The diff should help grip and handling:
They're usually not cheap:
Peloquin R32 Rear Diff
Good write up on the difference here:
VWVortex.com - Peloquin Rear Diff Test for the R32/TT
(I know he's talking about snow a lot but still...)
To be honest, I wasn't specifically looking for one. I was just doing the usual "S3" eBay search and up it came, a brand new one in Australia at a good price so rude not too
Hi sam, i actually got a peloquin in the front, i fitted it three years ago when the 1st and 2nd gear fork had snapped in two.
Be very carefull if you do your own install, it's not that straight forward, i had to shim out the part of the bearing that goes into the housing because the diff was 0.4 mm wide on the bearing seats.
Car feels like i have a blue haldex controller, some times i get 3 wheels spin, but on low speed tight corners i lose grip cause the inner wheel lifts off the ground.
Sorry to highjack westle.
Got my car back and it feels brand new! Took it reasonably easy on the turbo for 70 miles then couldn't resist putting my boot down. The new turbo is holding 25psi whereas the old one only 21psi. I'm not sure if this is safe as the car was mapped fueling wise for 21psi, I'll have to ask Bill about that.
Also when I got home I had 2 packages. 1, Badger 5 TIP and 2, the rear PCD adapters. Logging time tomorrow hopefully.
Nice one, i would hold of the 25psi bit though, or at least check the fueling...
Awesome stuff Neil, looking forward to your review on the things listed above and your results from the B5 TIP.
What 3" downpipe and de cat did you go for in the end.
Fit that TIP tonight and log tonight, you know you want to lol
Mate i am so jealous lol, glad its getting sorted.
What DP and decat you got?
Went pipeworx dp and decat.
I'm currently waiting on a reply from Bill regarding the 25psi as he mapped my car. This may delay my logging that I wanted to do but I'd rather not ruin anything else.
This wont stop me fitting the tie arms, poly bushes, TIP, and wheels this weekend but i just hate having a fast car I cant put my foot down in.
I may have to get my FMIC sorted and head back to Bill's for stage 2 and some map tweaking.
Yes mate! Good work, it's always hard to be patient and take it easy at first.
Looks like I might be taking it easy for a while yet running at 25psi!
Try waiting for 500+ miles and an oil change after rods - so hard!
Doesn't yours have a wideband lambda? I think that should help the car adjust if you do, might be talking out my bum hole though
Yeah it does have a wide band lambda but I don't think that will help much. I think all that'll happen is the ECU will pull timing like a biatch!
Mine I've seen mine add and take away fuel as necessary on dyno runs when trying to make some sense of my hybrid as it is.
I'll wait for Bill to reply to my PM anyway.
I could be in your neck of the woods again very soon
Yes mate! Ill pop over and say hi then
Bill has said he's a bit worried about 25psi on my stock bottom end. I'll try and get a date in the diary to come down to Gloucester in July to go Revo Stage 2.
Now I'm just off to try and remove a kidney to fund the FMIC I need to get on before the remap.
if you have unisettings and vagcom lead, you can wind down load scale to reduce boost, or if that does'nt work, n75 electrically off will make it safe.
I presume the new turbo's actuator is a little stiffer than the oldun perhaps, hence spiking more boost
stage 2 is generalyl smoother than stage 1 anyhows so it should all settle down.
I have VCDS lead so can I just download a copy of Unisettings? How simple is it to wind down the load scale?
Just downloaded unisettings 1.4 just hunting for a user guide. I'll run the car without the N74 to see what the actuator is set to.
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