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

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

    THIS GROUP BUY IS CLOSED! PRICING IS NO LONGER VALID! SEE UPDATED THREADS FOR MORE INFORMATION AND HOW TO ORDER.


    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.



    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.

    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
    Last edited by Def; 10-27-2013, 05:47 PM.
    '18 Chevrolet Volt - Electric fun hatch for DD duty!


    DefSport Koni Sleeve and Spring Perch Buy!!!
    http://www.nissanroadracing.com/showthread.php?t=5902

  • #2
    I will take one set

    Comment


    • #3
      Originally posted by Def View Post


      Your nuts are hairy

      Sorry I couldn't help myself
      '06 wrx - DD

      '89 s13 hatch - jackstand racing national champion

      Comment


      • #4
        I blame the brains behind DefSport:



        '18 Chevrolet Volt - Electric fun hatch for DD duty!


        DefSport Koni Sleeve and Spring Perch Buy!!!
        http://www.nissanroadracing.com/showthread.php?t=5902

        Comment


        • #5
          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)?
          Last edited by 2_Liter_Turbo; 05-20-2011, 10:05 PM.

          www.2LiterTurbo.com (Personal Site)
          96 240SX SE: Track Car | 90 Skyline GTR: Bucket List Car | 07 Legacy Spec B: The DD

          Comment


          • #6
            You guys sure are making me work for this list...
            '18 Chevrolet Volt - Electric fun hatch for DD duty!


            DefSport Koni Sleeve and Spring Perch Buy!!!
            http://www.nissanroadracing.com/showthread.php?t=5902

            Comment


            • #7
              Copy and add yourself to the list if interested:

              1. jbennett58
              2. 2_Liter_Turbo
              3.
              4.
              5.
              6.
              7.
              8.
              9.
              10.
              11.
              12.
              13.
              14.
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              18.
              19.
              20.

              Total: 2



              And yes, payment will be through Paypal.
              '18 Chevrolet Volt - Electric fun hatch for DD duty!


              DefSport Koni Sleeve and Spring Perch Buy!!!
              http://www.nissanroadracing.com/showthread.php?t=5902

              Comment


              • #8
                1. jbennett58
                2. 2_Liter_Turbo
                3. KNerd *4 lug*
                4.
                5.
                6.
                7.
                8.
                9.
                10.
                11.
                12.
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                Total: 3

                Comment


                • #9
                  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)

                  Comment


                  • #10
                    Passenger side rotor is straight vane and driver's side is directional/curved?

                    Put me down for a set.
                    97 Kouki SR 240

                    Comment


                    • #11
                      Hey steve, get rid of your megan coilovers before you buy brakes

                      I dont' think I can afford to jump in on this, unfortunately

                      Comment


                      • #12
                        1. jbennett58
                        2. 2_Liter_Turbo
                        3. KNerd *4 lug*
                        4. Bubba
                        5.
                        6.
                        7.
                        8.
                        9.
                        10.
                        11.
                        12.
                        13.
                        14.
                        15.
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                        Total: 4
                        Originally posted by Matt93SE
                        in engrish, it's all about the length of your shaft... :P

                        Comment


                        • #13
                          Originally posted by cdlong View Post
                          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)


                          Look at the outside radius for a 12.19" rotor. Spoke clearance is slightly better than Z32 30mm aluminum calipers by a few mm.
                          '18 Chevrolet Volt - Electric fun hatch for DD duty!


                          DefSport Koni Sleeve and Spring Perch Buy!!!
                          http://www.nissanroadracing.com/showthread.php?t=5902

                          Comment


                          • #14
                            Originally posted by 0wn3r View Post
                            Passenger side rotor is straight vane and driver's side is directional/curved?

                            Put me down for a set.
                            That's a Summitracing goof, they're both 32 curved vane rotors (that are linked, or you can go with 42 vane rotors). The Wilwood site lists stuff out pretty well if you want to see what else works as a 12.19x1.25" rotor with a 8x7 bolt pattern.
                            '18 Chevrolet Volt - Electric fun hatch for DD duty!


                            DefSport Koni Sleeve and Spring Perch Buy!!!
                            http://www.nissanroadracing.com/showthread.php?t=5902

                            Comment


                            • #15
                              Originally posted by e1_griego View Post
                              Hey steve, get rid of your megan coilovers before you buy brakes

                              I dont' think I can afford to jump in on this, unfortunately
                              Trust me, I'm working on it! Never even put the damn things on! lol

                              www.2LiterTurbo.com (Personal Site)
                              96 240SX SE: Track Car | 90 Skyline GTR: Bucket List Car | 07 Legacy Spec B: The DD

                              Comment

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