Porsche Brembo 996 BBK conversion

[Wernd]

Guys I need some help, I've looked back through these posts to 2022 and can't find the posts talking about rebuilding these calipers. I could have sworn I had seen them but now I can't find them.

I've now run them for 4 track events and have decided I really like this setup. I do need to get them powder coated and while I have them off I'd like to install new seals and hardware. Also, are there any upgrades other than the dust boot upgrades?

Any help would be appreciated

[heinzboehmer]

Does anyone how to remove these pins? I need to pull them out a bit.

https://nam3forum.com/forums/forum/main-forum/member-build-journals/195928-black-tan-332it?p=242409#post242409

[Tbonem3]

There's a pin underneath holding them in. They maybe tght and need to be pressed out. I never removed one, but I did have one that was well loose. I could tell it wants to rotate and slide, but I saw that little rolled up metal pin move when I moved the big pin, so I think it's holding it in.

[maupineda]

Does anyone how to remove these pins? I need to pull them out a bit.

[bavarian3]

Thanks for providing the pics maupineda . I just mounted mine up and they fit fine, like yours do. No rubbing, just spooked me at first.


With that closed, this project just keeps handing me gifts as I have a new dilemma. On the Megane (Freakyparts kit) front calipers, the radial mount bolts don't thread all the way through the brackets. The provided bolts are m14x80mm socket heads. The next size up is 90mm.

I'd like opinions on whether to:
1. use 90mm bolts and trim the bolt to avoid the knuckle.
2. use 90mm bolts and shave off knuckle to accommodate bolt
3. use the 80mm bolts as is...

Edit - I was able to locate 85mm bolts on amazon of all places. Nothing on Mcmaster, belmetric or boltdepot. I think these should do the trick, they are fully threaded however.

pics:

[maupineda]

I take that back, seems is a tight fit. I don’t have my feeler gages but is barely 1mm of clearance. I do not see any rubbing though.


I have more clearance to the bolt, but maybe is the photo angle on yours?



mine have about 12k of road use.

[maupineda]

Mine does not have that little of a gap. Have the car on stands, let me take a pic

[Tbonem3]

yes. It's a tight fit (the rotor to caliper), but no evidence of them touching.

[bavarian3]

I received a response from Rally Road. Still curious to hear others thoughts with experience with these.

"I don’t see anything wrong in the pictures. There’s variations from car to car and rotor to rotor, etc. There’s also no need for the bracket to mate with every part of the caliper mounting surface. Sure…we could have designed it that way but then it would cost $50 more with no benefit.
If the caliper is physically rubbing on the outside ring of the rotor, then I would clearance the caliper with a file. A millimeter of clearance should be enough.
If we moved the calipers further away, then the brake pads wouldn’t fit the same.
Everything looks just fine based on your pictures."

With all the work involved with retrofits, I see why BBK's cost what they do. Upon test fitting these look great however, excited to get em' running.


Tbonem3 Are you referring to the control arm balljoint bolt? No issue there.

[Tbonem3]

I remember having to file down part of that bolt head on a friend's 06 zcp. I personally have CM, but I'll be installing rear RR brackets on another friend's car soon.

[bavarian3]

Looking for advice here on rear 996 calipers with rallyroad brackets.

Does everyone have this tight of tolerance between the caliper body and the rotor? This doesn't seem to be enough space for heat expansion.

[I see there are some shims included with the rallyroad brackets, but I believe these are for horizontal spacing of the pins which I have no issue with.]





Also, are these supposed to hang over the brackets like this? I don't see any other way to fit these. Doesn't smell right.





Tbonem3 Arith2 heinzboehmer maupineda Obioban Nate047 D-O

[mdefalco25]

Just getting parts ordered for the 996 calipers but currently running with ARC 8s
Front: 18x9” ET30 with 245/40-18 tires
Rear: 18x10” ET25 with 275/35-18 tires

I’ve seen a few state that a 5mm spacer will work up front but Apex suggests a minimum of 3mm gap between spokes and caliper and that an 8mm at a minimum would be needed. Anyone confirm 5mm will work?

[Ramage]

I installed the front 996 calipers on my 2004 convertible yesterday.

The process was mostly straightforward, but I encountered one major challenge: the 16mm carrier bolts. There was an excessive amount of Loctite on these bolts, so I had to use heat and PB Blaster to remove them. Even after applying heat and the blaster, it was extremely difficult to break them free.

This issue was frustrating and turned what should have been a one-hour job into a three-hour endeavor. If anyone faces a similar problem, I recommend removing the discs to gain better access to the carrier, which will help you apply heat more effectively.

I used Rally Road brackets (older style that I bought back in 2013) and did not have to grind anything to achieve a good fit.

[robgill]

I run the following for track pads:

PFC 08 0776.08.16.44

PFC 08 0776.08.17.44

[Tbonem3]

Pfc z
ferodo ds2500