A Better rotor combo with Evo 8/9 Brembos

[JT020110]

Wanted to share some info for those of us that may had previously done the Evo 8/9 Brembo swap..Now personally myself I made this swap like 8 years ago and the last two items below have annoyed me and was tempted many times to go back to stock until I got a proper BBK.

For those who don't know, there are a few major downfalls/considerations to doing this swap.

-You have to modify the steering knuckle mounting ears or the calipers permanently to get the right offset to center the rotor in the caliper.
-Evo 8/9 rotors hub bore needs to be bored out to fit on our hub.
-Squishy pedal due to the larger caliper volume and the master cyl volume essentially not being able to keep up.
-Lastly the pads do not sit all the way onto the rotor due to the caliper mounting points being about 5mm too far from the center bore.

This post really only addresses the last flaw with the pad not sitting all the way on the rotor. Though I do have a couple ideas to address the master cyl volume that I may try dunno.

If you haven't seen the swap how to, here is a link to the one I used:

https://forums.mightycarmods.com/forum/technical/how-to-forum/29640-how-to-install-brembos-on-a-mazda6-mps

Here is are some photos of the Evo 8/9 Rotors with the 8/9 Brembos.

You can see that the pads hang off the edge of the rotor, and for me this created an unbearable brake squeal.


Stock Evo 8/9 front rotors are 320mm in diameter.
I found this site to be very useful that allows searches by size and put in the specs of the rotor I needed.

Search Brake Rotors by Size

Find rotors by size: outside diameter, product height, nominal and discard thickness

www.allrotors.com

So the main thing i needed was an additional 10mm in diameter and as close to the same offset/height as possible.
EVO 8/9 Rotors
Diameter - 320mm
Overall height - 43.4
Thickness - 32mm
Hub - 69mm

So I searched all rotors with 330mm diameter and a 43mm overall height and what I found was this guy. Thickness little thinner than I wanted but I figured that it might be doable.
2001 Mustang Bullitt
Diameter - 330mm
Overall height - 43.4
Thickness - 28mm
Hub - 71.1mm

So I took a chance on it and picked up a cheap set to test out. Brake Best Part # 66844RGS


And here it is mocked up


* I did have to take roughly .5mm of the center hub bore.




Now the rotor is 4mm thinner, so there is a possibility of uneven pad wear. I think could easily be offset with a 1 - 2mm steel spacer between the rotor and hub to get it closer, but I am going to see how this works out first without it. The inside pad is snug but the rotor still spins freely.

1st test drive went really well, no dead spots in the pedal due to more piston travel. I'm going to go ahead and put some new pads and hardware in to see how it goes.
So if you are really committed to making these work this may be a better option than the stock Evo 8/9 rotor.

 

[Enki]

Is there a reason the caliper cannot be moved 10mm closer to the hub to get rid of that overlap instead of having to get a different rotor?
Better yet, is there a way to get the caliper positioned correctly for factory rotors, even if that means custom brackets?

 

[90fish]

I saw somebody on instagram use focus RS brembo's and it seemed like less work than this solution. Is there a major performance gain for these over other BBK solutions?

 

[brandonf]

I'm using the evo 8 brembo's on my speed6, but I don't remember having to modify the rotors at all.. just bored out the knuckle slightly to mount up (although now that I think about it.. i did get them used, may have already been modified and am still using the same rotors/pads).

The squeal, is it while you're driving and not braking, or during braking.. i do notice a metallic noise sometimes, i just figured one of the caliper pistons might be getting stuck, because I didn't drive it for 8 years.

 

[JT020110]

Is there a reason the caliper cannot be moved 10mm closer to the hub to get rid of that overlap instead of having to get a different rotor?
Better yet, is there a way to get the caliper positioned correctly for factory rotors, even if that means custom brackets?

So yeah my original hope around fixing this went down this road. I had everything pulled apart to take some initial measurements and it ended up looking way more complicated to make a solid piece that could fit.

I’ve done a few very simple things in fusion and ordered them through send cut send. Very cool lol but this is a bit next level for me atm.


Sent from my iPhone using Tapatalk

 

[JohnnyTightlips]

So yeah my original hope around fixing this went down this road. I had everything pulled apart to take some initial measurements and it ended up looking way more complicated to make a solid piece that could fit.

I’ve done a few very simple things in fusion and ordered them through send cut send. Very cool lol but this is a bit next level for me atm.


Sent from my iPhone using Tapatalk

If you have a 3d printer you could design and print and test fitment without having to pay tons of money for a final part until you are ready. I have been doing that and it is awesome.