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GenII Brake Upgrade w/o breaking the bank?

Discussion in 'Gen 2 Prius Accessories & Modifications' started by Justdidit, Oct 17, 2012.

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  1. Justdidit

    Justdidit LVNPZEV

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    I only started looking into the upgrade when I see that its been done b4 already on the Prii.. with no ill effects mentioned:

    'Tri-Garage' - IS350 BBK swap
    [​IMG]

    Minkara - The Car & Automobile SNS
    'Tri-Garage' - LS460 BBK swap
    [​IMG]

    Minkara - The Car & Automobile SNS
    'Tri-Garage' - LS460 BBK swap
    [​IMG]

    Minkara - The Car & Automobile SNS
    'Tri-Garage' - LS460 BBK swap
    [​IMG]

    Minkara - The Car & Automobile SNS
    'Tri-Garage' - LS460 BBK swap
    [​IMG]

    Minkara - The Car & Automobile SNS
    Celica - Rear disc upgrade on a G2 Prii
    [​IMG]

    Minkara - The Car & Automobile SNS
    ARMA Brake Systems
    [​IMG]

    Minkara - The Car & Automobile SNS
    ARMA Brake Systems
    [​IMG]

    Minkara - The Car & Automobile SNS
    ARMA Brake Systems
    [​IMG]

    Minkara - The Car & Automobile SNS
    ARMA Brake Systems
    [​IMG]

    Minkara - The Car & Automobile SNS
    ARMA Brake Systems
    [​IMG]

    Minkara - The Car & Automobile SNS
    Wilwood pro-six 330 Roter
    [​IMG]

    Minkara - The Car & Automobile SNS
    4-Pot Top Secret System
    [​IMG]
     
    #61 Justdidit, Dec 10, 2012
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  2. Britprius

    Britprius Senior Member

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    I notice the Celica upgrade uses the old 4 stud rear discs that were used on the gen1 Prius in the UK the later 5stud discs are the same as the gen2 Prius.
     
    #62 Britprius, Dec 10, 2012
  3. 69shovlhed

    69shovlhed Surly tree hugger

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    you need to find a japanese friend to translate. and he/she might be able to hook you up w/ whatever shop is doing it. looks like they do all kinds of radical mods over there.
     
    #63 69shovlhed, Dec 10, 2012
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  4. Justdidit

    Justdidit LVNPZEV

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    Looks like this place... Anyone speak Japanese??

    I sent them an email...

    http://www.try-car.com/

    [​IMG]
     
    #64 Justdidit, Dec 10, 2012
  5. semo.pz

    semo.pz Junior Member

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    Just to clarify, this upgrade is not for normal circumstances. I need it for circumstances that require seatbelts and airbags (i.e. in emergencies). So like I said, I’m looking for something that is better than stock but not performance oriented. Pound for pound, some performance parts can be worse than OEM when cold or rusted over.

    Also, something mundane such as picking up people from the airport can be very taxing. Will the stock brakes make full use of the available traction with an extra 300kg load on board?
    Hopefully they've cracked the regen and stability control issues highlighted by Britprius. If you could buy all the parts (so no fabrication) I'd be really interested. Keep us posted (y)

    EDIT: any idea what would be the smallest rim that will fit over these 4 pot brakes? I prefer to have as much rubber as possible between the my wheels and the curb :)
     
    #65 semo.pz, Dec 11, 2012
  6. Justdidit

    Justdidit LVNPZEV

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    I haven't gotten all the measurements yet, but I'm pretty sure the Toyota 231mm 13WL 4 pot calilper will fit in my stock Prius G2 Touring 16" wheel as this upgrade worked on the stock 16" 4Runner wheel w/o grinding the caliper down. Tight fit, but did work. Stock Diameter of the rotor is 254mm (10") and this upgrade would go up to 316mm (12.6") Its not the rotor I'm worried about clearing the wheel, but rather the Caliper. As I do more mods I'll get closer to fabbing this up. The Caliper will not be a direct swap a caliper bracket will have to be fabbed but a very simple design. However since i seem to be the only one doing this at this point, the fabricators usually will only do a bracket if I order more than 3-5 after I hand them a design. So if all works out, I'll have extra brackets to sell off. (Same for my MAF housing I'm having fabbed for the new intake - will have extra of those as well.)
     
    #66 Justdidit, Dec 11, 2012
  7. Justdidit

    Justdidit LVNPZEV

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    Lexus IS350 Caliper and 334mm rotor swap:
    Brackets: ?TBD
    334mm Cross drilled and slotted Rotors: $175 ea from a VW R32 AWD Golf
    Non- PowderCoated Calipers: $130 ea
    PowderCoated Calipers: $740 (Core:$260) = $484
    Upfront costs:
    Regular Caliper $610
    Powdercoated Caliper $1090

    Tundra 13WL Caliper and 316mm rotor swap:
    Brackets: ?TBD
    316mm Cross drilled and slotted Rotors: $120 pair from a Subaru Legacy GT 3.0L
    Non- PowderCoated Calipers: : $110 ($80 core charge return if u can find some old crummy ones to send back) $110
    PowderCoated Calipers: $275 (Core: $80) = $195
    Upfront costs:
    Regular Caliper $320 w/o a refund on cores - $240 after core refund
    Powdercoated Caliper $405 w/o a refund on cores - $325 after core refund
     
    #67 Justdidit, Nov 6, 2014
    Last edited: Jun 22, 2015
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  8. a_gray_prius

    a_gray_prius Rare Non-Old-Blowhard Priuschat Member

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    I'd argue that it's more of a show upgrade - it's certainly heavier than stock, and you're probably not exceeding the rotor heat capacity doing autocross runs. Have you ever locked the wheels up braking? If you have, then you need better tires first - try the ADVAN AD08R or A048s. I ran the AD08s at 42psi - lots more grip, but lots more rolling resistance and your acceleration rate will suffer although lateral grip, braking, and steering response will be much improved. My focus has been on reducing weight (especially unsprung mass), but I haven't yet been successful in finding a lighter brake kit.
     
    #68 a_gray_prius, Nov 6, 2014
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  9. Daves09prius

    Daves09prius Active Member

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    Semo.pz I find it funny that you said this, "Just to clarify... Pound for pound, some performance parts can be worse than OEM when cold or rusted over."

    I'm not trying to be an a$$ -- just an observation, My OEM rotors are NOTHING but rust! It seems like Toyota didn't zinc plate or treat the rotors in anyway to prevent rusting, and wow are mine rusted. They don't need to be replaced due to wear: the surface isn't grooved or pitted - but there is so much rust on the inner cooling veins, that I'm afraid that one day I'll have to do an emergency stop and the calipers will crush the rusted out rotors.

    That's why my my rotors will be replaced by aftermarket rather than OEM, with OEM I know I'm getting rotors that will rust immediately. Aftermarket, may or may NOT rust out... I'll take my chances.
     
    #69 Daves09prius, Nov 7, 2014
  10. 69shovlhed

    69shovlhed Surly tree hugger

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    I had zinc plated rotors from ebay. they looked much better but the quality might not have been the same. since my'06 rotors looked good, I just left em on the '04 when I sold it. I bought those plated rotors because the oem rotors had rusted so badly. but they did have > 180k miles.
     
    #70 69shovlhed, Nov 7, 2014
  11. Justdidit

    Justdidit LVNPZEV

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    Update: Pulled the trigger - went ahead and ordered Calipers and Rotors. As soon as they arrive, I'll start designing the mounting brackets for the Lexus IS350 Caliper to fit over the VW RS32/Audi TT 13.1" rotor - all to go on my lil NHW20 2007 Prius hubs.

    Caliper upgrade from Stock Prius 1 piston caliper to Lexus IS350 4 piston Caliper
    Rotor upgrade from Stock Prius Diameter of the rotor is 254mm (10") to Audi TT rotor of 334mm (13.1")

    [​IMG]

    I don't expect the fab work to be done super quick - but I'm excited about moving forward with this quest. :)
     
    #71 Justdidit, Jun 22, 2015
    Last edited: Jun 22, 2015
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  12. 69shovlhed

    69shovlhed Surly tree hugger

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    wow! I hope it works good. please take lots of pix!
     
    #72 69shovlhed, Jun 22, 2015
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  13. Justdidit

    Justdidit LVNPZEV

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    Parts are starting to roll in.

    Left Rotor
    [​IMG]
    Rotor Dimensions
    Diameter: 345mm
    Height: 49.8mm
    Thickness: 29.9mm

    Left Caliper
    [​IMG]

    [​IMG]

    This stuff is MASSIVE...

    There were cheaper rotors and calipers I could've ordered...but I thought I'd get pretty good quality if I am gonna do this anyway.

    Currently ordered the following parts:

    Stoptech Power Slot Brake Rotor 126.33094SL
    Stoptech Power Slot Brake Rotor 126.33093SR
    Cardone Industries 19-3337 Front Left Rebuilt Caliper With Hardware
    Cardone Industries 19-3336 Front Right Rebuilt Caliper With Hardware
    Bendix D1118 Front Ceramic Brake Pads
     
    #73 Justdidit, Jul 7, 2015
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  14. Justdidit

    Justdidit LVNPZEV

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    Oh man... ran into a unforeseen issue. but first...some pictures..

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Which brings me to the problem - the rotors for the VW R32 V6 won't work as they do not have the correct spacing and won't allow the caliper to fit on the rotor with the wheel.

    [​IMG]

    I will have to source another rotor that will allow for the correct placement of the rotor which pushes the caliper further away from the wheel.

    Probably will do a IS350 rotor and have the bolt pattern redrilled from 5x114.3 to 5x100. Also thinking about doing the IS350 Stoptech blanks instead of doing drilled or slotted. So much research show that solid rotors will assist with the pads and rotors working in conjunction together with the best longevity. Unless cast holes are used, drilled rotors tend to crack after heavy use. Slotted assist for better braking during use in AutoXing but shorten the life of the pads. Solid Rotors will prove in this situation to last the longest all around - just won't look as 'Cool' - lol

    I think the bracket should be fairly easy to fab up once i have the correct placement of the Rotor. I will probably either remove the dust shield or trim it to fit the placement of the IS350 caliper as well.

    Disappointing yet still fun at the same time.
     

    Attached Files:

    #74 Justdidit, Jul 16, 2015
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  15. 69shovlhed

    69shovlhed Surly tree hugger

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    you might consider a vw rear rotor. it would still be way bigger than oem, but will have backspacing because of the e-brake shoes. you'd probably need a smaller caliper though. if it was me I'd want some powder coated brembos...

    also, since the car uses regen most of the time I wouldn't be real worried about longevity. the dinky stock brakes last so long the rotors rust out before the pads need to be changed. I wish someone would make stainless car rotors. they squeal easier than iron but they sure look good.
     
    #75 69shovlhed, Jul 16, 2015
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  16. Justdidit

    Justdidit LVNPZEV

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    I'll definitely look into it as an alternative. Currently ordered Stoptech blank IS350 rotors and will have them redrilled to our 5x100 bolt pattern

    Will end up having the calipers look like what I did on my 4Runner using Tundra Calipers.

    [​IMG]

    A 'TRD red' with a high temp white vinyl logo clearcoated on.

    SM-G870W ?
     
    #76 Justdidit, Jul 16, 2015
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  17. Agent J

    Agent J Hypoliterian

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    Can you do a comparison of braking distance before and after this project? Just curious on the difference a bigger brake makes and also how the ABS will cope. Best to do it in the wet, i think. :rolleyes:
     
    #77 Agent J, Jul 16, 2015
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  18. Justdidit

    Justdidit LVNPZEV

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    My top choices were:

    StopTech Crossdrilled (128.44137R)
    StopTech Crossdrilled (128.44138L)
    or
    StopTech Slotted (126.33094SL)
    StopTech Slotted (126.33093SR)
    or
    StopTech Premium (125.44170L)
    StopTech Premium (125.44171R)

    I ended up deciding on the Premium High Carbon Brake Rotor because they were only $65ea... Can't wait for them to arrive - getting items delivered thru Canada customs is a PITA. Miss the ol SoCal free shipping.
    [​IMG]

    Once I design the bracket and have tested these out, maybe I'll grab the slotted or drilled set for comparison.
     
    #78 Justdidit, Jul 20, 2015
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  19. Justdidit

    Justdidit LVNPZEV

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    Primed grey then a close fit to a 'TRD red' - I think this color with some black vinyl letters will fit in with my car nicely..

    [​IMG]

    Still waiting on the hi-temp vinyl TRD letters before I clear coat these.
     
    #79 Justdidit, Aug 6, 2015
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  20. 69shovlhed

    69shovlhed Surly tree hugger

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    I don't want to be a bummer, but I just thought -- how can we know if the brake system is capable of delivering enough volume and pressure to fill those huge-looking 4 piston calipers? and is the abs system gonna freak out with christmas lights?
     
    #80 69shovlhed, Aug 7, 2015
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