Brake upgrade - 986 Forum - The Community for Porsche Boxster & Cayman Owners

andicati · 02-23-2005, 12:07 PM

Does anyone have any experience in completely changing out their brake system on a Boxster?

Background: things can get out of hand pretty quickly. It all started when my brake light came on and I realized I would be in need of new rotors at the front. I started to shop around for upgrade kit options and discovered they were outrageously more expensive than I could afford. Not to be deterred, I bought some slightly used 996 TT brakes through eBay. Rotors, pads, calipers, all in perfect condition. Now I have 80% of the Twin Turbo braking kit available through www.********************************************.com. Surely the Porsche wheel carriers required to fit the calipers to the fornt end won't be tto diffcult to find? How wrong I was. They are on back order from Porsche Germany - wait time of 10 months minimum. Not to mention the pretty pricey too. So, being fairly handy, I will attempt to manufacture my own wheel carriers. If I can get the important dimensions, I will design the items in CAD and have them CNC machined from billet of even machine them myself. In order to jump start the project, I am now trying to reesearch all there is to know about actually changing out the rotors/calipers on a Boxster or 996 or that matter. Brave or Stupid? You decide. But the box of parts in the garage has me committed.

ps, I am doing the brake upgrade in part for aesthetics, and in part in anticipation of some serious additional HP via a supercharger or a 996 motor conversion.

mrssito · 02-24-2005, 11:46 AM

Well, I'm not even a Porsche guy, so no experience with the brake swap. But I admire your approach. Not too many guys or gals understand that going fast has as a prerequisite being able to stop FAST.

You might check out emachineshop.com - integrated design software and machining services. Design using their free CAD program, and then they have the part manufactured in whatever material you want.

Brucelee · 02-24-2005, 12:53 PM

I can attest to the fact that stopping is useful!

Good luck with the project!

Fletcher · 02-25-2005, 01:45 PM

The front brakes on Boxsters can easily go between S and Non S versions (simply bolt on). Going beyond that is unknown to me other than the brembo kits you see for 4k everywhere.
Your kit is obviously different. Try parts heaven for some used ones (hub carriers). Someone has got these I'm sure. How about Carnewal in Europe? There are lot's of places to try before machining your own. Pick up and Excellence, GT, and Porsche and 911 world magazines from your local Borders book store and start calling and emailing....happy hunting

andicati · 02-27-2005, 06:29 AM

Fletcher, thanks for the tips. Wish you hadn't pointed out Carnewal. They have some sick stuff. Looks like I am going to have to get a job.

Pilot2519j · 02-27-2005, 05:31 PM

I would check out Orton located in ATlanta. Ask for Neil. They do all sorts of work on the Boxster check the site for yourself.
http://www.ortonperformance.com/

JFP in PA · 02-28-2005, 02:05 PM

The easy way to convert a base to S braks is with the Brembo kit (~$3,000). Direct bolt on, no hub swaps or any other nightmares. I've done three, the Brembo Kit has everything you need. Trick to the kit is it has specially machined rear rotors that work with the base ebrake system. No fuss, not bother and replacement parts are readily available from Brembo.

Brucelee · 02-28-2005, 02:28 PM

For 3 large, I would drive more slowly!

andicati · 02-28-2005, 05:57 PM

Brucelee hit the nail on the head. 3k is a steep price to pay to avoid the headaches. There is nothing sweeter than simple bolt on kit but the way I look at it , if I can get the job done, even with headaches, AND I save some coin in the process, the feeling will be even sweeter. When I eventually get started, I will post some blow by blow pics.

By the way, the equivalent bolt on kit using the Twin Turbo brakes retails at 4.5k!

Brucelee · 02-28-2005, 06:06 PM

If it were me, here is the way I would handle a brake job. I have a very good, very reasonable mechanic who charges me about $60 per hour to work on stuff he can handle.

With a brake job, he can handle that fine.

I then go and find the parts, which I get at dealer cost. I bring them to him and I am usually out the door at 50% or less than Porsche dealer cost.

Obviously, I cannot do that on many Porsche repairs but when I can, I do.

I hope that helps somewhat.

Good luck''

JFP in PA · 02-28-2005, 07:29 PM

I've tried the twin turbo brakes, and while the mass due to the size difference will help disapate heat, I am yet to find anyone that has overwhelmed the S brakes...... In reality, brakes can become too large, and then you need to add more tire to compensate. "Seek balance, cricket".

And, unless I'm mistaken, the TT brakes will require a new master cylinder and brake bias system as well....................