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Rear brake upgrade

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  • #46
    Right, so where were we? That's right, carriers that didn't fit.
    Que Gavin and his care package of carriers that did fit.



    On the left are the bora v5 carriers, on the right are the s3 carriers. Small differences but they matter.

    Then I had some dramas with the calipers, the pistons wouldn't wind back for some reason or another.
    Given that the car was off the road and I didn't want waste more time, Que Gavin again with another set of calipers.



    Voila it all fits up.

    Old:


    New:


    If you ignore the dramas that I had it's a relatively straightforward job.

    Points of note:

    I cut the dust guard with my dremel, you don't really need to remove much get a reasonable amount of clearance.

    The handbrake was interesting.
    I backed off the adjustment in the cabin to remove and refit the cables.
    There is a clip that secures the cable sheath to a bracket on the caliper which is hard to get on compared to the stock setup due to the caliper being a little bit further out now but is do-able. Being tight won't be an issue regarding suspension travel given how it's secured to the rear torsion bar.

    I borrowed a power bleeder from TDIfan to do the bleed which made that aspect a complete breeze.

    In the photos are my track rims which are ET43. Caliper clearance is tight but seems ok.

    Not sure what is up with the first set of calipers. I've had a look inside them and they look ok. I'll strip and may rebuild/refirb, worry about it later.
    Last edited by rgvlee; 23-11-2015, 11:55 AM.
    08 9n3 Polo GTI
    Mods: heaps

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    • #47
      Glad I can help Lee
      06 Polo TDi

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      • #48
        Well a couple of months on and with a track day under my belt, hows about an update

        I haven't got any before an after track times but can definitely run deeper into braking with these on. I'm able to completely shoot past the braking markers now.
        Previous trackdays would have abs coming on right before tip in to sharp turns.
        I don't think I got any abs hits with the bigger rears.
        The back end used to squirm a bit as well, don't seem to get that anymore.

        Pretty happy with it, I think it was worth the effort.
        08 9n3 Polo GTI
        Mods: heaps

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        • #49
          Just purchased a complete v5 bora rear axle from Matt at Camden GTI. it'll be a couple of weeks till they're on the car but it gives me time to get my **** squared away. For those who've played this game before:

          Why cut the dust shields and not just remove?

          Sent from my GT-I9505 using Tapatalk

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          • #50
            Originally posted by Bullet Fast View Post
            Just purchased a complete v5 bora rear axle from Matt at Camden GTI. it'll be a couple of weeks till they're on the car but it gives me time to get my **** squared away. For those who've played this game before:

            Why cut the dust shields and not just remove?

            Sent from my GT-I9505 using Tapatalk
            The stub axles stop them coming off easily.

            Gavin
            optimumcode@gmail.com | https://www.vwwatercooled.com.au/for...i-;-79012.html | https://www.facebook.com/TTY-Euro-107982291992533

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            • #51
              Originally posted by h100vw View Post
              The stub axles stop them coming off easily.

              Gavin
              Yeah... I'll see about that [emoji6] got the right calipers and carriers though. Pretty stoked. Rotors are at 21.3mm. Hoping I can have have some local guy skim both for less money than a single new rotor, though at $48 a rotor I'm not holding my breath.



              Sent from my SM-T800 using Tapatalk

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              • #52
                Originally posted by rgvlee View Post

                They still look tiny, get some of these https://www.ecstuning.com/Volkswagen...e/Rear/ES4519/
                MODS- TOO MANY

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                • #53
                  Don't see the point these work pretty well.
                  08 9n3 Polo GTI
                  Mods: heaps

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                  • #54
                    Originally posted by vwthunder View Post
                    They still look tiny, get some of these https://www.ecstuning.com/Volkswagen...e/Rear/ES4519/
                    Or get smaller rims
                    Resident grumpy old fart
                    VW - Metallic Paint, Radial Tyres, Laminated Windscreen, Electric Windows, VW Alloy Wheels, Variable Geometry Exhaust Driven Supercharger, Direct Unit Fuel Injection, Adiabatic Ignition, MacPherson Struts front, Torsion Beam rear, Coil Springs, Hydraulic Dampers, Front Anti-Roll Bar, Disc Brakes, Bosch ECU, ABS

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                    • #55
                      So I finished mine a while ago. Kept the stock rotors with a skim and through the remsas back in. They're still bedding and will be for a while I'd say.

                      I tried to replace the rear lines too but the braided sections I have are 2mm too large for the mounts. If I could have got stepped drill in the I would have changed that but oh well...

                      I'm still not convinced on polo brakes. Sure. I can lock up the wheels. I'm sure they fade less now. Balance is a little better though seems a little oversteery on hard braking now which is fun...

                      Just figured I'd get a bit more immediacy out of of the brakes! Thinking about it, I'm sure heavier spring rates again would help, less camber maybe. Bleed is good, remsa pads front and rear. Just not the authority I was hoping for. I said to Gav a couple of weeks back I think I'm spoilt from the monoblocs on sport bikes on hot slicks.

                      I'll look at bumping up a tyre category from pilot sports, but considering the cornering potential of the car as it is easy the chassis is the weak link.

                      That and I don't like the dead travel in the brake pedal.

                      Anyone tried upping the master cylinder size!?
                      Last edited by Bullet Fast; 05-06-2016, 11:56 PM.

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                      • #56
                        Originally posted by Bullet Fast View Post
                        So I finished mine a while ago. Kept the stock rotors with a skim and through the remsas back in. They're still bedding and will be for a while I'd say.
                        So what are you running exactly? The Bora calipers on a stock rotor? That doesn't sound right being the bora calipers would be designed for a vented rotor, not a solid (and skinny) polo rotor.

                        What fronts do you have, stock?

                        The stock sized stuff even with DBA rotors and good pads aren't what I'd call authoritive. Add some braided lines, bigger rear is nice. Gavin and Louis both have 312mm fronts, I've ran Gavin's car on the track, it stops well, similar pedal travel to stock, so good modulation and much better at high speed over stock. It's not brembo, but ample competent.
                        Track Car: 06 Polo GTI Red Devil mkII
                        Daily: 2010 VW Jetta Highline
                        Gone but not forgotten: 08 Polo GTI
                        ** All information I provide is probably incorrect until validated by someone else **

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                        • #57
                          I've got the 312mm front and 256mm vented rears. Braided lines front, the rears won't fit, yet. Remsa pads front and rear.

                          Yes it feels as though nothing has been modified. Nice safe modulation, good feel. I guess a little soft for my preference and of course, any softness in a chassis with such high cog and short wheelbase is going to manifest as a disconnect between pedal and response. Just a shame really.

                          Sent from my GT-I9505 using Tapatalk

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                          • #58
                            Hoyhoy.

                            I upgraded both the front & rear to Audi Mk1 TT 225 which do help a lot, then pads are a big thing as well, (I can cook Ferodo 2500's easily, Ferodo 3000's were the answer.) then cooling is a real big benefit, then the Master Brake Cylinder Stopper is a massive improvement, braking the Little Blue Girl on the street is out of this world, it's a solid pedal.
                            All this is from a lot of trial & error, a lot of labour & love went into the final result which is dam good.
                            All this is only needed if ya want to get dam good times when going serious on the track.

                            To Improve Me Polo. - Page 9
                            Hooroo.

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                            • #59
                              I bet the brace would help a heap actually. Hmm.

                              Sent from my GT-I9505 using Tapatalk

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                              • #60
                                Originally posted by Bullet Fast View Post
                                I've got the 312mm front and 256mm vented rears. Braided lines front, the rears won't fit, yet. Remsa pads front and rear.

                                Yes it feels as though nothing has been modified. Nice safe modulation, good feel. I guess a little soft for my preference and of course, any softness in a chassis with such high cog and short wheelbase is going to manifest as a disconnect between pedal and response. Just a shame really.

                                Sent from my GT-I9505 using Tapatalk
                                That should all be well up to task for any street oriented driving. Remsa's are fine for light track work, which still far exceeds street speeds. Hill climbs and what not, remsa should be fine too. I run QFM A1RM's on the front which to date have been adequate for my track driving. Yes, I could still brake later and marginally harder if running a more aggressive pad, but it's acceptable for me.

                                I haven't looked into the master cylinder brace beyond seeing what Eddy has done.
                                Track Car: 06 Polo GTI Red Devil mkII
                                Daily: 2010 VW Jetta Highline
                                Gone but not forgotten: 08 Polo GTI
                                ** All information I provide is probably incorrect until validated by someone else **

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