135 6-piston OEM Brembo Retrofit... The DIY.

[Chad44]

************************************************** *********************************
* As you know with any other DIY your proceeding at your own and sole risk, I'm not liable for anything. *
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I got tired of thread jacking other people's posts so here's my DIY for retrofitting the OEM 135i e82, Gray 6 Piston Brembo calipers onto an e46 or e36. This would also work for the yellow calipers if you were so lucky as to find a pair in need of a rebuild, as they are mechanically identical.

I am just starting this build, as the piston rebuild parts just showed up today, but I should have everything completed in the next few weeks to complete my DIY writeup, at which point I will post my final layout to the DIY section.

Parts you will need to start:
(2) Front 135i performance 6 piston calipers.


https://lh6.googleusercontent.com/-4SY81TY9e3E/T06R_8AYXuI/AAAAAAAAD58/H16tvVxowys/s800/P1030140.JPG


(2) Oem 135i caliper mounts that come with the 6-piston calipers.

https://lh4.googleusercontent.com/-p8j4EyLRMOc/T05BJngjGxI/AAAAAAAADys/m_FkUmkfrCg/s800/P1030107.JPG


You can source these parts wherever you want or can... I got mine from a fellow BMWCCA member (thanks LarryN).

If you find a set with healthy ceramic caps on the pistons, and you don't intend to take your car on the track, you might be able to just use the calipers as they are, only requiring a modification of the bracket to get these installed on your car.

The factory bracket mounts right up to the e46/e36 brake mounting points, but the 135 had a 338mm rotor diameter, where the e46 330 rotors used with this retrofit are 325mm. This requires us to do some modifications of the bracket to move it 6.5mm in to properly sit on the rotors.

here's a photo of the calipers and brackets, as it comes from the factory for the 135, this photo is without brake pads(and just for clarification, you obviously use 135i brake pads, not 330 pads)

https://lh4.googleusercontent.com/-oN0QmSXxRws/T0nheI76laI/AAAAAAAADug/Uizmg9Jxl7A/s800/IMG_0643.JPG



In my case, I do plan to track the car, and the previous owner removed them because he fried the piston's ceramic caps, boots and etc. So, mine required a rebuild. I did some research and was able to find most of the information I needed on what to order but was almost misled by a few posts into ordering the incorrect parts... that's partially why I chose to put together a complete front to back DIY for this project.

Here are some photos of what happens to these on the track...

https://lh4.googleusercontent.com/-BPlRx8j5hUI/T05BKd_8CFI/AAAAAAAADy0/a4-65pW33tc/s800/P1030109.JPG

https://lh6.googleusercontent.com/-bF_bnjwrEQ4/T05BK3OouRI/AAAAAAAADy8/gbLg_uBB5TM/s800/P1030110.JPG

https://lh4.googleusercontent.com/-RMOVVSsYjkQ/T05BOgxnF7I/AAAAAAAADzw/SJm3TQ7k9Uw/s800/P1030117.JPG

https://lh5.googleusercontent.com/-YXwFxC31Z50/T05BPtOg1FI/AAAAAAAAD0A/vIW0VyDXVyg/s800/P1030119.JPG

https://lh6.googleusercontent.com/-tznqGlgFzpI/T05BQkCN1bI/AAAAAAAAD0Q/xL8ExEdDTmc/s800/P1030121.JPG


Don't be worried by these photos, the brakes shold be perfectly fine, just needing new pistons and dust boots, but while you're in there just replace the compression seal also.

[Chad44]

This is a link to the google album that hold ALL the photos I take along the way... (https://picasaweb.google.com/101251472935703528827/1356PistonBremboOnE46330iZhp?authuser=0&authkey=Gv1sRgCKmarcTK84_8AQ&feat=directlink)

[Chad44]

I will be modifying the brackets in the coming weeks when I find time to set up the milling machine to do so...

But, for now- I'll be laying out what is needed to rebuild the calipers with new pistons.

I ordered complete rebuild kits online, these kits come with 2 pistons, 2 pressure seals, and 2 dust boots each. This means that you must order 2 of each sized kit (28mm, 32mm, 36mm) in order to rebuild a pair of calipers.

Parts ordered, and price I paid:

$363.36Stoptech rebuild kits Incl. Aluminum short pistons, Pressure Seals & Dust Boots
-(2) StopTech Rebuild Parts (143.99128) For ST-28 Calipers
-(2) StopTech Rebuild Parts (143.99132) For ST-32 Calipers
-(2) StopTech Rebuild Parts (143.99136) For ST-36 Calipers

https://lh4.googleusercontent.com/-E4RyJyG9mp8/T04-9PRlGzI/AAAAAAAAD0g/WcUiatHljBg/s640/P1030136.JPG

https://lh5.googleusercontent.com/-dTH1QJd3cZw/T04_BGW-GpI/AAAAAAAAD0c/15dpyllXRjI/s640/P1030129.JPG

https://lh4.googleusercontent.com/-NrPLvcU28g8/T04_APz1-1I/AAAAAAAADx8/2IDmYdIUhQE/s640/P1030131.JPG

https://lh4.googleusercontent.com/-b4-tRFIy-bs/T04-_cl45JI/AAAAAAAADx0/pJLBGt3PiKk/s640/P1030132.JPG

https://lh3.googleusercontent.com/-frlnc7Z6Sgc/T04--OPw0GI/AAAAAAAADxk/XGerYNZmf-k/s400/P1030134.JPG

This is as far as I have gotten so far, I will rebuild the calipers in the next few days and then update the thread.

[Chad44]

When it comes time to rebuild the calipers, the first thing you need to do is clean them... they are likely very dirty and cleaning them before hand will keep you clean(er), and help to keep dirt and debris out of the calipers that could damage the piston bores...

I cleaned mine 3 times with a brush and engine degreaser, which got most of the crap off them and whats left I will just be careful not to dislodge... The primary thing is to hand clean and wipe down all surfaces around the pistons as this is the most likely culprit of knocking crap into the piston holes..

Once clean, we work on removing the old pistons... Mine were crumbling and gave me nothing to hold them with... and while I was playing with them last week I had managed to push the pistons all the way into their bores.

I used air from my air compressor to get the pistons out enough to grab them with a set of water pump pliers. For this, you need to put something in the middle of all the pistons to keep them from popping out, since as soon as one breaks the seal you have no pressure and the others will not pop out. I used a couple pieces of wood.

https://lh6.googleusercontent.com/-EgO3ZMGDImc/T06SC3tkneI/AAAAAAAAD68/LIC1k497rCU/s800/P1030148.JPG

https://lh3.googleusercontent.com/-2QjRnwcHclA/T06SDiWuaHI/AAAAAAAAD7M/3ws2ovXWkIk/s800/P1030150.JPG


Once they are out, enough, grab them and pull them out.... twisting helps here. I wrapped the jaws of my pliers in electrical tape so as not to mark the surfaces, just in case... though I'm planning to throw the old pistons away, who knows... maybe I'll make aluminum caps that press into the old pistons, allowing them to live again...

https://lh6.googleusercontent.com/-tXWYbpPqHXg/T06SEr7p19I/AAAAAAAAD7c/TeuokWD-EiQ/s800/P1030152.JPG

https://lh4.googleusercontent.com/-0cXKreOyzlg/T06SFO2lejI/AAAAAAAAD7k/LBQnXCVcbtI/s800/P1030153.JPG


The next step is to remove the old dust boots and pressure seals.
For this, I used a small electronics screw driver, getting it into the edge of the seam and giving it a few gentle taps with something helps to get it down below the metal ring of the dust boot, then it pries out very easily.... repeat for all 6 boots.

https://lh3.googleusercontent.com/-BP_OmpXmI6A/T06SFmLWOGI/AAAAAAAAD7s/SNQ2Iw7cAt8/s800/P1030154.JPG

https://lh3.googleusercontent.com/-pnuSJ_f1SyE/T06SGjg-jDI/AAAAAAAAD78/r3lXzSZwFUE/s800/P1030156.JPG


Here's a look into the piston bore at the pressure seal. When removing the pressure seal be extremely careful not to scratch or nick the aluminum walls.
I used 2 small precision screw drivers, one to get the seal out of the groove, and the other to pull it away. This may be able to be done with your fingernails, but I had just cut mine the night before.

https://lh3.googleusercontent.com/-6WuXkQnRIZM/T06SHetH6cI/AAAAAAAAD8M/em-UMZL3CzA/s800/P1030158.JPG

https://lh3.googleusercontent.com/-kmKhcmuYNSQ/T06SH4ANprI/AAAAAAAAD8Y/q0UxVMyq9G4/s800/P1030159.JPG

https://lh6.googleusercontent.com/-HwdTu1PoyoQ/T06SIk-BBcI/AAAAAAAAD8k/Wx2xWcLfu24/s800/P1030161.JPG

https://lh5.googleusercontent.com/-3Y7_QM3-A_w/T06SI3CfvJI/AAAAAAAAD8w/qdBHVkGGU8w/s800/P1030162.JPG


https://lh5.googleusercontent.com/-SU9plsA0uSc/T06SeLO6v-I/AAAAAAAAD9A/4eM-QE6Ma64/s800/P1030163.jpg



Once all the dust boots and seals are removed, carefully clean the area around the pistons again, and inside the piston bore... but be careful not to leave any paper or cotton fibers from your cloth.

I laid out all my parts and had a look at the new and the old, this is where things went wrong for me...

https://lh3.googleusercontent.com/-gHGhs9VzlR0/T06Sfp4OqRI/AAAAAAAAD9c/sKpZx9KhJmE/s800/P1030166.JPG

https://lh6.googleusercontent.com/-VdrNZ2QS24Q/T06SgGsb3wI/AAAAAAAAD9g/CYpbd-2A1V8/s800/P1030167.JPG

https://lh5.googleusercontent.com/-wTx9jwMdhY4/T06SgqkMV9I/AAAAAAAAD9o/iCv9xH_M7PM/s800/P1030168.JPG

https://lh6.googleusercontent.com/-MvduXkeNbFw/T06ShJsrb4I/AAAAAAAAD9w/xBXVoJeIb2c/s800/P1030169.JPG

The company had shipped all the correct parts, except the 32mm pistons were not correct, they had put 34mm pistons in the kit... so as soon as you get your parts, it's a good idea to check to be sure they are correct.
This can be done easily without measuring tools; the dust boot is printed with it's size. The pressure seal nests perfectly inside the dust boot and came shipped to me in this way. So far you can confirm the size of those two parts that way, next you take the pressure seal out of the dust boot and it should slip easily over the piston, a perfect fit... this is how I knew mine weren't right- they didn't fit the rest of the kit.

Anyways, getting back to the process- carefully put the new pressure seals back into the grooves using only your fingers. Also be sure that the seal is seated flat and is not twisted.

Once the seals are in, you can put the dust boots onto the pistons, making sure that you pull them down until the boots fits correctly in the groove.
Then, use some fresh brake fluid to lubricate the piston bore, pressure seal, and new piston... carefully push the piston into the bore, making sure it is straight.

I found that the 28mm pistons pressed in fairly easily with some light spinning, but the 36mm required a bit more grunt than I could give them with my fingers... so i took a large metal clamp, wrapped the ends in electrical tape, and pressed them in slowly, only proceeding when I was sure that the pistons were straight in the bores and that the piston was started in the pressure seal... the fought for a second them pressed right in easily.

https://lh4.googleusercontent.com/-XUUUXXaWv7A/T06ShTQEtNI/AAAAAAAAD94/vOyu2nNFjxQ/s800/P1030170.JPG

The final product... sans my 32mm piston that I will have to wait for to finish.

https://lh3.googleusercontent.com/-R9bikAfkED0/T06SmDPQeJI/AAAAAAAAD_Y/AAdPrJuGDO8/s800/P1030181.JPG

[Chad44]

Bracket modification place holder.

[Mtnman]

Sweet. Subscribed.

[spencers]

Subbed fo' sho'

[danewilson77]

Thanks for the DIY Chad.

HTC Thunderbolt+TT

[UdubBadger]

nice. never woulda sold my 135i Performance Brake kit if I knew they'd fit this car.

[derbo]

Those parts should work out! :)

[cakM3]

looking good so far Chad! Subscribed :thumbsup

[Chad44]

It's snowing and my night class was cancelled so I broke out one of the calipers and started working on it!

First things first, there has been a snag in the process... Stop Tech put the incorrect sized pistons in both of my 32mm rebuild kits... both kits have 34mm pistons in them!!! I could have had both calipers rebuilt by now if this had not happened!

I called stop tech to discuss the piston thing, and they were helpful but the guy told me that the bmw 135 calipers use different parts than the ones I ordered. I took a ton of measurements(plus the 28mm and 36mm are already installed) and there are only minor differences. The kit they have for rebuilding the 135 brakes is only available in house, and is not sold to the public "only the manufacturing department has them".

The critical mechanical dimensions are exactly the same, the length of the piston and the diameter of the piston... I am assuming that the reason they say they will not work on the 135 calipers is a political reason.

The head of the stop tech piston is a different size than the original, but more critically; the groove that holds the dust boot is a different size. This means that if these were on a 135m and the owner had upgraded the pistons to stop tech but tried to use oem replacement dust boots, they would not fit... Which is a non issue for me, since I assume the stop tech dust boots are meant to take a bit more heat and wear than the oem ones were.

The head size of the piston may bother some, but it doesn't bother me, and it's up to you to make that decision... The surface area of the piston that touches the brake pad is smaller than that of the original pistons, and while there could be some draw backs to that design, I see it as a potential help in eliminating one of the reasons these fail in the first place... the smaller head will allow for a smaller amount of heat build up in the pad backing... potentially saving the brakes, allowing them to last longer, etc... I don't know, this is all theoretical but it's what I'm going with since it makes sense to me.

Here are some photos of the differences between pistons:

https://lh6.googleusercontent.com/-r7h4JrL7ca0/T06Sh2hoNrI/AAAAAAAAD-A/lS_7JKF7M4o/s800/P1030171.JPG

https://lh5.googleusercontent.com/-QfMEgz1r4Hg/T06SikyM7JI/AAAAAAAAD-I/vIfZUe1avwU/s800/P1030172.JPG

https://lh5.googleusercontent.com/-B55r6D3pkqU/T06SjVflJvI/AAAAAAAAD-g/P-A9Y1mt040/s800/P1030174.JPG

Stock pistons in the caliper:

https://lh4.googleusercontent.com/--RIewGNF5FA/T05BN-ji9eI/AAAAAAAADzg/8RqDtTwAPIk/s800/P1030115.JPG


Stop Tech pistons in the caliper:

https://lh3.googleusercontent.com/-R9bikAfkED0/T06SmDPQeJI/AAAAAAAAD_Y/AAdPrJuGDO8/s800/P1030181.JPG

[Chad44]

I just updated the beginning of the thread with the caliper rebuild info...

[UdubBadger]

damn puttin in werk bro

[cakM3]

Chad does not mess around when it comes to BMWs :thumbsup Great work Chad!!!

[Chad44]

Thanks, I got excited and wanted to play with my new toys... Now I have to do a return RMA with the incorrect pistons, then wait for them to confirm them and send me some new pistons. Hopefully I'll find the time and cutting bit to get these brackets shaved down this weekend.


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[derbo]

Interesting find! So is stop tech going to give you 32mm pistons or are they going to send you prototype pistons :)


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[Chad44]

Interesting find! So is stop tech going to give you 32mm pistons or are they going to send you prototype pistons :)


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Oops, I thought I responded to this days ago... No prototype pistons, just going to send me the right pistons... I'm still waiting for thmotorsports to give me an RMA # so I can send them back.... Hoping to hear from them Monday.


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[bullfrogs_M3]

Subscribed. Great work Chad. Looking forward to the caliper bracket modification. Curious to know how and where to modify the bracket.

[UdubBadger]

I have stock 135i brembo pads if anyone wants um.


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[Chad44]

I have a set of stocks lightly used, and I'll be running them on my current rotors until the summer, then I'll replace the pads with hawk, and rotors with performance rotors so I'm all good...


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[zj96sc]

You need a pick set!

Lookin good.

[Chad44]

You need a pick set!

Lookin good.

I'm assuming you're saying that for removing the pressure seals... I have a set but couldn't be bothered to go find them when the small screw driver trick worked so easily.

Also, I'm still waiting on the pistons. I heard back from THmotorsports last night, just before their closing time, and they asked for photos proving the pistons were the incorrect size(stop tech required them). So, i took photos and sent them off immediately, and once again got an email back from them just before they closed tonight saying that they sent the photos off to stop tech, and are awaiting a response... I really hope they can pick up the pace so I can finish this project.

I ordered BMW performance rotors yesterday, and new carbide C6 tipped milling bits for my fly cutter... hoping that I can get the brackets cut down this coming week while I am on spring break.


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[Chad44]

Still waiting; I have not heard back from THmotorsports or Stop Tech, and am rather annoyed at this point... I provided proof that stop tech packaged the incorrect piston a week ago, yet I haven't been able to get a word as to when I will receive replacements from them.


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[derbo]

:[

[cakM3]

Still waiting; I have not heard back from THmotorsports or Stop Tech, and am rather annoyed at this point... I provided proof that stop tech packaged the incorrect piston a week ago, yet I haven't been able to get a word as to when I will receive replacements from them.


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Darn! I was looking forward to an updated status....hopefully you will hear from them soon....

[Chad44]

I sent them an ugly email last night, so we will see what they say today. I wast rude, I just outlined my disappointment with their process, I'm thinking about contacting stop tech directly today, but I'll wait a little bit and give THMotorsports a chance to respond.


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[UdubBadger]

That sux


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[Chad44]

New pistons will be here on Thursday... It's about time to get this project finished. But the cutting bits I bought to make the new brackets also got held up with the invoice getting lost in the system- This project is not having good luck!


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[cakM3]

Chad,

You will get this done and have new calipers mounted. Should look awesome when you get everything sorted out :thumbsup

[Chad44]

Stop tech only sent 2 pistons... Now I'm waiting again to find out why. The bits for my fly cutter bit showed up on Thursday also, but the milling machine is buried behind a pile of cabinets now... Should have the floor edges sanded and the whole floor urethaned by next weekend... Then I can start cutting the brackets... Of course my car goes to the body shop on Monday, so I'll have to do my test fitting on my mother's 330cic. The two pistons I received will at least let me finish the caliper rebuild part of the DIY.


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[Chad44]

At the urging of Charlie, I'm throwing out a little update... I installed the last 2 pistons in the one caliper so I have one rebuilt caliper, but I have new plans a-brewing for the brackets and rotors...
The new plan:
Buy front M3 CSL rotors(345mm x 28mm)

Make (very hard metal) shims to space caliper bracket out from the center of the wheel.

The 135i rotors are 338mm, so by adding 3.5mm (1/8") spacers, I should be able to clear the m3 rotors perfectly.

The only thing left is the rotor thickness... The 330i rotors are 25mm, but the 135 rotor is 26mm so I only need to clear an additional 2mm(1mm per side)

If there are clearance issues I can sand 1mm off either pad, but I doubt there will be problems.

Will update further when I get my car back from the body shop next weekend and can test fit... Hoping to get the CSL (ZCP) rotors ordered Monday.

Another interesting bit of info is if you plan to track your car and the semi-floating performance rotors aren't up to your punishment, you can use aftermarket m3 2 piece rotors on your car... Only having to deal with the same potential clearance issues between 25mm and 28mm clearances.



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[derbo]

CSL rotors are mad expensive! I wonder if they will sell you the brackets for the 345mm?

http://www.schmiedmann.com/3_series/E46/Equipment_-_accesories/tuning/page5.htm#1939917

From what I can tell these guys use CSL 345mmx28mm Rotors

http://static.schmiedmann.dk/ProductPictures/image_58113_big.jpg

[Chad44]

I shouldn't need to buy new brackets, I have the 135 brackets that hold the caliper in place to clear a 338mm rotor, so by adding a 3.5mm shim it will be moved out by the difference and clear the 345mm rotors... this is in theory somewhat but based on measurements and info I have gathered. Also, the CSL rotors are no more expensive than the performance rotors for the 330i... $225 ea. on www.thebmwpartstore.com plus shipping...

[Chad44]

The Schmiedmann site is down right now, but I did find the kit you're talking about and yes that is exactly what I'm looking to do... so I guess I don't have to worry about it fitting because it's already being done... SWEET! My build will come in SIGNIFICANTLY less than the $2900 they charge... and I still have the upgraded pistons!

[Chad44]

Their website is back up and their price is actually just shy of 1500... So that's a little more than I will have spent... Not a bad price for the kit, but the ceramic piston cap is still there as a potential problem.


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[derbo]

Well remember that the Ecs tuning setup uses 330i performance rotors which meant any 330i rotor would've worked.

The setup you are making with the zcp rotors is what I want. I just need to remember that it might not clear 17" rims.


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[Chad44]

I think the 17" wheels I have will clear the calipers with the added 1/8", but only time will tell. I have 18s to run anyway, but I'm hoping to keep my 17" winters usable.


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[derbo]

I hope so too. If your setup works well with then 345mm. I might have to consider it!!


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[terraphantm]

CSL rotors are mad expensive! I wonder if they will sell you the brackets for the 345mm?

http://www.schmiedmann.com/3_series/E46/Equipment_-_accesories/tuning/page5.htm#1939917

From what I can tell these guys use CSL 345mmx28mm Rotors

http://static.schmiedmann.dk/ProductPictures/image_58113_big.jpg

Those aren't CSL rotors. The hats are too thick. Maybe E9x M3 rotors?

Edit: never mind, I just realized that what I thought was part of the hat was just a thick spacer.


At the urging of Charlie, I'm throwing out a little update... I installed the last 2 pistons in the one caliper so I have one rebuilt caliper, but I have new plans a-brewing for the brackets and rotors...
The new plan:
Buy front M3 CSL rotors(345mm x 28mm)

Make (very hard metal) shims to space caliper bracket out from the center of the wheel.

The 135i rotors are 338mm, so by adding 3.5mm (1/8") spacers, I should be able to clear the m3 rotors perfectly.

The only thing left is the rotor thickness... The 330i rotors are 25mm, but the 135 rotor is 26mm so I only need to clear an additional 2mm(1mm per side)

If there are clearance issues I can sand 1mm off either pad, but I doubt there will be problems.

Will update further when I get my car back from the body shop next weekend and can test fit... Hoping to get the CSL (ZCP) rotors ordered Monday.

Another interesting bit of info is if you plan to track your car and the semi-floating performance rotors aren't up to your punishment, you can use aftermarket m3 2 piece rotors on your car... Only having to deal with the same potential clearance issues between 25mm and 28mm clearances.



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The only aftermarket 2-piece rotors I'm aware of in CSL sizes are the ones racing brake sells. But since their sales were so low, they're using the 335 rings with M3 hats - which makes the rotors 345x30. The M3 brakes do clear them, but you might have an issue since you'd have 4mm to accommodate for rather than just 2.

[Chad44]

After doing the research on the CSL rotors, and the less than stellar track performance ratings, I sent back the rotors and decided to just go with an e46 m3 blank rotor... in the long run, it will be a crap load cheaper, and I need to stop dumping cash into this car and start buying things for my remodel. I just finished my finals, so I can breath again, but need to work in the apartment so I can gain access to the milling machine again, as it is currently surrounded by kitchen cabinets while I finish sanding, and coating the hardwood floors... This project may get put on hold a bit longer than planned, since I just took on 16 credits in summer school and will only have time to go to class, study, eat and sleep for most of the summer.

[UdubBadger]

need stock pads? I have some FS

[terraphantm]

After doing the research on the CSL rotors, and the less than stellar track performance ratings, I sent back the rotors and decided to just go with an e46 m3 blank rotor... in the long run, it will be a crap load cheaper, and I need to stop dumping cash into this car and start buying things for my remodel. I just finished my finals, so I can breath again, but need to work in the apartment so I can gain access to the milling machine again, as it is currently surrounded by kitchen cabinets while I finish sanding, and coating the hardwood floors... This project may get put on hold a bit longer than planned, since I just took on 16 credits in summer school and will only have time to go to class, study, eat and sleep for most of the summer.

Out of curiosity, what did you read specifically about the rotors? I can't imagine them being worse than the M3 blanks or euro rotors.

M3 calipers and pads on the other hand definitely not really great for track duty. I would think a fixed caliper would take care of that (though the 135i caliper in particular has its own issues with heat)

[derbo]

shame cause I was waiting for 345mm rotors ;) lol

[Chad44]

I figured at $500 a pair for the csl rotors, or $70 a piece for the blanks, I could afford to have spares of the blanks... Not so much with the csl rotors.
I read about them on m3forum.net I believe, I read it in. Few places that they didn't offer a big advantage over the blanks on the track, so I'll take the cheaper option..


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[derbo]

it makes sense. Besides benefits is that 17" rims fit over the 330i factory size rotors :)

[derbo]

any updates on this chad?

I also found some good replacement pistons for the 135i cracking problem!

http://www.racingbrake.com/category-s/7030.htm

a little expensive but its Stainless steel which makes they great! Expensive as hell though.. $630.00 :\

[az3579]

any updates on this chad?

I also found some good replacement pistons for the 135i cracking problem!

http://www.racingbrake.com/category-s/7030.htm

a little expensive but its Stainless steel which makes they great! Expensive as hell though.. $630.00 :\

Screw... that.
The Turner ones are expensive enough. :shifty

[derbo]

I'll wait till these get cheaper. I'm not a fan of factory setup at the moment.


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[Chad44]

I was planning to wait a little before releasing this info... But here's a little project I have in the works....
http://img.tapatalk.com/d/13/03/18/abuze4ub.jpg
Those are all 28mm, 304 stainless pistons... I'll be making a batch of 32mm an 36mm pistons this week, and have a tester set up to street and track test my pistons. Over the next few weeks. Stay tuned... I'll probably start a new thread for this though.
I will also have the brackets made soon, possibly this week also.


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[Chad44]

And my price will be less than the racingbrake pistons... I'll have to finish my runs in order to figure out the final cost, but I've simplified the machining a little in order to reduce cost, while retaining the thermal barrier and hardness benefits.


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[cakM3]

Awesome Chad!!!

Sent from my DROID RAZR HD using Tapatalk 2

[danewilson77]

May want to take the discussion to PM.

Sent from the HTC DNA, Williamsburg, VA and USA

[UdubBadger]

wish someone would get smart and produce the shims for $99

[Chad44]

I'm waiting on approval for promoting the sales of these parts through the forums, but I'll update another photo. I have two full sets made- one for myself, and one for testing at the moment, however I can have more sets made in no time.

http://img.tapatalk.com/d/13/03/19/su5uzury.jpg



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[UdubBadger]

Awesome.


- Goin' H.A.M. Mobile

[Chad44]

If anyone is interested, send me a pm for now, until I figure out terms for the mafia... I'm gauging interest before I actually have any sets made for sale... I have one set for myself, as one being track tested by another member soon.

I did a science experiment with him last night when he came to get the pistons, showing him why stainless is a better material for the job.
I chilled a StopTech aluminum piston and one of my stainless pistons in the freezer for 2 hours, then placed them on a cast iron skillet that had been heated to 600 degrees Fahrenheit.
When the pistons were placed on the skillet for about 30 seconds, the back side of the pistons were measured for temperature(the part that would normally be in contact with the brake fluid).
In this case, the aluminum piston had transferred the heat through itself to the back side, heating to 145 degrees, while the stainless piston had only warmed to 85 degrees.
This low heat transfer coefficient of stainless steel, allows it to better act as a thermal barrier, transferring less heat into the brake fluid, lowering the likelihood of boiling the brake fluid.



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[Marcus-SanDiego]

Chad, I sent you a PM.

[Chad44]

Chad, I sent you a PM.

Thanks- I saw it, and will keep in contact as things progress! Looking forward to seeing you in May.


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[Chad44]

It's been a while, but I am 3d printing a bracket this week for test fitting, then will be making the brackets soon after the final dimensions are confirmed.

I also machined a set of the stock brackets this week in order to get them mounted on my car... I'm getting my powder coated rig setup, and my oven running to powder coat the calipers.
Original and machined brackets.
http://img.tapatalk.com/d/13/05/27/2eture6a.jpg

Bracket setup on my old-arse mill in the garage!
http://img.tapatalk.com/d/13/05/27/ehesune8.jpg

Here's a close up of the fitment with everything mounted up... M3 rotors, stock 135i Calipers and pads, and machined brackets.
http://img.tapatalk.com/d/13/05/27/edygy4ev.jpg


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[UdubBadger]

Nice progress!


- Goin' H.A.M. Mobile

[derbo]

Are these the stock 325mm M3 rotors? or the 345mm Rotors? Judging by the lack of the semi-floating rotor pins, I would say it's the 325i Rotors.

[Chad44]

They are the stock 325mm rotors, but I plan to make available brackets to fit the 345mm rotors as well, I can't clear them with my 17" OZ's, so I won't be running them... The options for affordable rotors in the ZCP 345mm sizing turned me away from that setup myself.


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[330i ZHP]

interesting - anyway to drastically reduce the weight of the caliper?

[Chad44]

I'm not going to modify the caliper... Those beasts are staying as-is... I can't afford to play games with trimming them down... I am trying to get my hands on a set of the F10 M5 6 piston calipers to play with though, but realistically I can't afford those until I can get them from a wrecked car, or if I get some good sales on these brackets. Once these are in production, I'll be focussing on making the rear calipers fit, then I'm moving onto making these fit e46 m3's, then who knows... Only time, money and customers will tell, so if you want to see some interesting things, get your friends interested in my brackets and rebuilt caliper sets!!!


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[UdubBadger]

Nice, you have a tester waiting patiently here when you get the M3 ones out. :biggrin

[Chad44]

Nice, you have a tester waiting patiently here when you get the M3 ones out. :biggrin

Sounds great! Im looking for spindles/knuckles and suspension components from an m3 so i can do mock-up and fitting. Charlie has graciously offered the Because-Charlie-mobile for me to get measurements, but i'd also like to have one on hand for easier access. I may be picking up a front setup tomorrow, if all works out- I'm cash poor at the moment, so I have to sell some things to buy others! A few minutes ago, I found both sides of front spindle, lca, shock, sensors, rotor, caliper for $300 so i'm trying not to pass up the deal.... I'll have a bunch of parts I don't need and can sell if you need any of that stuff!

[UdubBadger]

Yeah I know that feeling :(

[Chad44]

3D printing the bracket prototype...

http://img.tapatalk.com/d/13/06/01/e9erunyj.jpg


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[Chad44]

A screen shot of the solid works part.

http://img.tapatalk.com/d/13/06/01/3a4ahe3u.jpg


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[danewilson77]

Way cool stuff Chad.

[ryankokesh]

That. Is. Awesome.

I need to buy stock in that 3D printing stuff...

[Chad44]

Some more fun stuff-
A video of the printer making the bracket, I have never used one before so I found it very cool to watch.
(It takes 6 hours to print a bracket btw)
http://youtu.be/PztePZ32ULw

And a video of the solid works part being rotated in the program. (Not as cool as the printer, but I'll share it anyway)
http://youtu.be/upwykcZ64ps



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[Tnhl1989]

3D printing is going to be sold at staples soon. Lol

[Chad44]

The bracket is $36 worth of the special plastic the machine uses, so I could only guess how hard and fast staples would bend me over to do a similar part... Even regular printing is stupid expensive there...


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[330i ZHP]

amazing, amazing stuff...this technology, your ability to use it...just amazing

KUDOS

[Chad44]

amazing, amazing stuff...this technology, your ability to use it...just amazing

KUDOS

Thanks, I'm excited to have access to the equipment. Fortunately, I'm working with a good friend of mine on this business venture- he is a manufacturing technology student, so he has access to the tools, and is trained in solid works, material machining practices, etc... I drew the bracket on paper, then in 2D CAD, then he took my stuff and made it 3D and is tutoring me in the solid works as we go as well... So, I can't take all the credit, but I'm hoping that between the two of us, we can make a proper go at doing this and not have it fizzle and die, like this same project last year.
I also spoke with a manager at my local dealership yesterday, who is having someone call me back about gaining access to their parts department to start cross-referencing, and documenting stock parts dimensions such as rotors, calipers, brackets, etc... That's exciting because the parts I wanted to measure currently would cost me over a grand if I had to buy them to test fit/measure.


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[danewilson77]

Thanks, I'm excited to have access to the equipment. Fortunately, I'm working with a good friend of mine on this business venture- he is a manufacturing technology student, so he has access to the tools, and is trained in solid works, material machining practices, etc... I drew the bracket on paper, then in 2D CAD, then he took my stuff and made it 3D and is tutoring me in the solid works as we go as well... So, I can't take all the credit, but I'm hoping that between the two of us, we can make a proper go at doing this and not have it fizzle and die, like this same project last year.
I also spoke with a manager at my local dealership yesterday, who is having someone call me back about gaining access to their parts department to start cross-referencing, and documenting stock parts dimensions such as rotors, calipers, brackets, etc... That's exciting because the parts I wanted to measure currently would cost me over a grand if I had to buy them to test fit/measure.


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I'll be sending you a pm shortly regarding a French contact.

HTC DNA ON TT4 BETA, WILLIAMSBURG, VA

[Chad44]

Sounds good!


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[chris]

The precision and speed of our 3D printer at work puts that to shame. It's incredible how fast the technology is moving. Wish I was better at solidworks :)

[Hermes]

just wondering, but will a complete front and rear upgrade require a new brake master?

[Chad44]

The precision and speed of our 3D printer at work puts that to shame. It's incredible how fast the technology is moving. Wish I was better at solidworks :)

Yeah, the printer we have is a little old, but it's a community college so we're lucky to have one at all.

[Chad44]

just wondering, but will a complete front and rear upgrade require a new brake master?

It shouldn't, but I was looking to see if there were any options available for upgrading myself anyway... I didn't see any options, do you know of any? I was thinking about looking at modifying an extra one I have, but I'm worried about needing to change the abs profile as well... Ill just try it when/if I get the rears sorted out.

[Chad44]

Also found something interesting when I was stripping the paint from the calipers today... The Brembo calipers have two large weights on them, that can be removed. The weights are usually used to stop an audible resonance, so they can be removed without sacrificing any performance, and actually reduce the unsprung weight on the corner of the car.

The weights are 328 grams each, for a total of 1.45 lbs!!!!! That's a considerable weight savings.. I noticed it when I took off the parts to look at them that they were much heavier than the aluminum I was expecting them to be...
The caliper weighed in at 7.8 lbs without the weights on it, so that's 9.25 lbs total.... I'll be leaving them off myself.

http://img.tapatalk.com/d/13/06/02/dy3yhate.jpg

Here the calipers are after a few hours of learning how to use aircraft stripper, and doing some final cleanup with a wire brush.

http://img.tapatalk.com/d/13/06/02/u7a7uhed.jpg

http://img.tapatalk.com/d/13/06/02/bu6y8ery.jpg

http://img.tapatalk.com/d/13/06/02/muvyvymu.jpg

http://img.tapatalk.com/d/13/06/02/hyha3etu.jpg

[330i ZHP]

very nice - also makes them not look dumb...I never liked those weird protruding pieces

[Chad44]

very nice - also makes them not look dumb...I never liked those weird protruding pieces

Agreed- that's why I was taking them off in the first place, but to find out there's a functional reason is just a bonus!

[Hermes]

It shouldn't, but I was looking to see if there were any options available for upgrading myself anyway... I didn't see any options, do you know of any? I was thinking about looking at modifying an extra one I have, but I'm worried about needing to change the abs profile as well... Ill just try it when/if I get the rears sorted out.

I don't know of any, but the reason I thought of it is from what I know when upgrading 02 brakes. What 02 guys use are later version master cylinders that displace more fluid, therefore can deal with more pistons in front and the caliper vs drum upgrade in the rear. Perhaps the master cylinder from the 135 fits the E46 booster and solves the problem? The brake bias can be easily adjusted using available aftermarket parts (Wilwood makes one that I've seen installed in 2002 race cars).



As for how the calipers look without those weights, I agree that it is much better looking with them removed

[Chad44]

Volumetrically, it is quite a bit different set of brakes, and I have calculated the bias, and volume differences in a spreadsheet.
As for the 135 cylinder- that's a no go, I researched it a few weeks ago and it has a different connection to the pedal and diaphragm... I shouldn't say it's not possible, just not plug and play. If I can come across a master cylinder/diaphragm/reservoir
I would certainly be willing to see if I could make it work... The m3 has slightly better sizing, but there are some differences that I can't quite work out without having one in front of me.


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[Whitexi]

Volumetrically, it is quite a bit different set of brakes, and I have calculated the bias, and volume differences in a spreadsheet.
As for the 135 cylinder- that's a no go, I researched it a few weeks ago and it has a different connection to the pedal and diaphragm... I shouldn't say it's not possible, just not plug and play. If I can come across a master cylinder/diaphragm/reservoir
I would certainly be willing to see if I could make it work... The m3 has slightly better sizing, but there are some differences that I can't quite work out without having one in front of me.


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So what your saying is you need to borrow Charlie's M3 for a bit....

Glad to see this project is going well.

[Chad44]

YES, most definitely; 3-4 months should be perfect... Very complex measurements they are... :biggrin:


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[UdubBadger]

hahaha

[az3579]

very nice - also makes them not look dumb...I never liked those weird protruding pieces

Dunno, I disagree with this. I think it looks better with the end pieces on.
That is the reason I kept them on.

[Chad44]

Dunno, I disagree with this. I think it looks better with the end pieces on.
That is the reason I kept them on.

You're welcome to your opinions! I will have to wait to have mine on to decide on looks.

Also- I'm going to powder coat two sets of these soon, I have a few color options- which colors would you guys suggest I do the two sets, I'd like to do 2 different colors.
These are the powders I have currently:
HIGH TEMP BLACK METALLIC
HIGH TEMP BRUSHED BRONZE
MAYAN GOLD BLACK
Sun Gold
Yellow Sun
SUPER DURABLE WET RED

I'm inclined to go sun gold or bronze on my personal set.


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[Chad44]

Anyone interested is welcome to email me at ChadsBMWparts@gmail.com.

Also, here's some more fun stuff... Bracket is done, tapped and test fitted.
http://img.tapatalk.com/d/13/06/05/9anyzuze.jpg

http://img.tapatalk.com/d/13/06/05/yqesajy4.jpg

http://img.tapatalk.com/d/13/06/05/uzuje6yz.jpg

You can see a little caliper surface inside the pad edge, so we will be bringing that in .038 inches in the solid works, then hoping to get a test run in aluminum on Friday, though I have decided the final brackets will be made from steel due to the proximity of the bracket to the pads, and the high heat seen during track use causing the aluminum to anneal and soften, turning a T6 aluminum into T4 or so... Anyway, I digress.
http://img.tapatalk.com/d/13/06/05/ty5ysese.jpg


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[Chad44]

Things have slowed just a little because of summer school, but I will update when I have more to share.


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[Chad44]

http://img.tapatalk.com/d/13/06/26/tevypype.jpg
Mounted a stock set up to my car to see how stock pads feel without any biasing modifications, but I'll be swapping a master cylinder and working on the rear setup very soon.
As expected, it's too forward biased, but my rears are a bit soft as it is. I'm replacing my rear rotors and have some hawk pads that I'll install and that should shift the bias back a little bit- I need anything I can get for autocross as it would not be ideal with the brakes setup as they are now.


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[chris]

Nice!

[Chad44]

A better photo I shared on the "what did you do for your BMW today" thread... I gave the wheels a good wash, and I'm really falling in love with them in the stock color!!!
http://img.tapatalk.com/d/13/06/28/4u7ebesu.jpg


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[cakM3]

Chad...looks good! :thumbsup Hopefully you will find a solution to get the rear calipers mounted :)

[330i ZHP]

https://www.facebook.com/hackmotorsport?hc_location=stream

[danewilson77]

Looks nice Chad. Well done.

Sent from my HTC6435LVW using Tapatalk 2

[UdubBadger]

A better photo I shared on the "what did you do for your BMW today" thread... I gave the wheels a good wash, and I'm really falling in love with them in the stock color!!!
http://img.tapatalk.com/d/13/06/28/4u7ebesu.jpg


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Great work dude, now get on making some M3 shims for me! ;)

[az3579]

Chad,
No issues to report with the effing awesome pistons you made for me. :)

Sent from my DROID RAZR MAXX HD