S brake conversion & caliper rebuild

[ekam]

I just thought I'd make a quick post here about my S brakes conversion & caliper rebuild. I got a set of used S calipers from fellow board member "Fred Demara" as he's parting out his car.

Cleaning:
At first I tried to spray them with brake cleaner which was not a good idea as the mix of grease & brake dust wouldn't come out at all. Off I went to get a bottle of Simple Green and everything comes right out with a tooth brush.

Rebuild:
I've contacted Jim @ zeckhausen.com to order the dust boots & inner seals since Porsche do not sell the inner seal (they believe their calipers do not need rebuilding - or you have to buy new set of calipers from them, ha!) Jim was very useful on looking up the size of the dust boot & seals.

I've ordered the following from him which is complete set.

Fronts
2 x 40mm Caliper Rebuild Kit - 2 Dust Boots & 2 Seals (143.99040)
2 x 36mm Caliper Rebuild Kit - 2 Dust Boots & 2 Seals (143.99036)

Rears
2 x 30mm Caliper Rebuild Kit - 2 Dust Boots & 2 Seals (143.99030)
2 x 28mm Caliper Rebuild Kit - 2 Dust Boots & 2 Seals (143.99028)

I also called guys at Suncoast to order the following:
- pads
- bleeder valves
- spring kits
- caliper bolts
(dampers & wear sensors are missing here since I can reuse the current ones.)

For front rotors, I've ordered the Performance Friction 2-piece rotors from Dan @ VividRacing.com. Again the parts were shipped very quickly.

I'm waiting to take the calipers off to my friend's workshop to pop out the pistons, then they're off to get powder coated.

Oh I've even got a dozen Porsche stickers made for $20 at a local vinyl shop.

The front brakes will be done first as I'm still collecting parts for the rears as they're NOT drop-in and slightly more complicated (requires fitting parking brake assembly from the S as well as getting caliper/rotor spacers available thru FVD Germany.)

I'll update this thread again once I get more updates... thanks for reading!

[Cloudsurfer]

Oh the joys of caliper rebuilding! I am very curious to see how the 2-piece rotors work out though as I am leaning toward these when I do rotors on my car.

[ekam]

Inner seal, dust boot and pistons are all out (along with a nice amount of green brake fluid!) Will drop it off for powder coating tonight.

[Sammy]

Would you be willing to weigh the 2-piece rotors as I am considering the upgrade as well? I am extremely curious as to the actual weight difference.



Sammy

[ramo80]

a cost total would be awesome as well!

[ekam]

Originally Posted by ramo80

a cost total would be awesome as well!

It's going to be over $3k Canadian money for all 4 corners using OEM stuff when it's all said and done.

After this there's going to be no more mods I swear...

[ekam]

Originally Posted by Sammy

Would you be willing to weigh the 2-piece rotors as I am considering the upgrade as well? I am extremely curious as to the actual weight difference.



Sammy

I'll weight them but I don't have a stock S rotor weight to compare it to. Dan from Vividracing said it saves about 1-2lbs each corner.

[Sammy]

Originally Posted by ekam

I'll weight them but I don't have a stock S rotor weight to compare it to. Dan from Vividracing said it saves about 1-2lbs each corner.

If all else fails I'll pull one of the rotors off of my car and weigh it (2002 S).

[ekam]

The rear S brake conversion is being done at a local reputable shop as we speak. I have just been told by the shop that Boxster S rear spindles are required to get the rear parking brakes to function. Thankfully I bought a used set for this project as a "just in case".

[jb92563]

Its great that you are continuing your thread on the conversion but
I couldn't help but notice that it was a 2.5 year project?

Glad that work is not being paid by the hour.

[Lobo1186]

Hey ekam i know this thread is old... but what is the final outcome? what parts were needed to put the s brakes in the back?