Lets Talk About Brake Ducting

ConeKiller said:
@Maisonvi

Fantastic thread. I'm more than happy to contribute 3d printed prototypes, measurement mock ups, etc.
I also have a spare set of brake shields, a welder and some sheet metal.

My 3 may not need it right now, but the racecar 6 definitely does. 3 & 6 rotors are very similar, except that the 6 is further offset from the hub face. @xfeejayx

I also have a bunch of tubing designed for brake ducts around.


Good ideas and Inspiration from the evo world:
Album including 3d printed protoype-
http://s132.photobucket.com/user/jid2/media/103_1384.jpg.html
Click to expand...

Assuming the mounting is the same, I will release my drawing for the dust shield when Im done and anyone can make them. I plan to just use spacers to get it right close to the rotor. Im mimicking the stock dust shield to an extent because its still a daily car. Im getting quotes on laser cutting now, its too much work to cut by hand.
 
Maisonvi said:
I think I can run a 2" duct under the half shaft, but over the LCA if I make a mount so that it wont move. Played with the steering and compressing the suspension and it seems to have worked out. That would put the duct super close to the center of the rotor with the whole opening inside of the actual rotor.
Click to expand...

Excellent.

The nice thing about SCAT is you can flatten it a bit and the wire will hold its shape so you flatten it a bit between the LCA and axle to allow for adequate clearance and use Adel clamps to secure it to the LCA so it doesn't flop around.
 
ibcrusn said:
Excellent.

The nice thing about SCAT is you can flatten it a bit and the wire will hold its shape so you flatten it a bit between the LCA and axle to allow for adequate clearance and use Adel clamps to secure it to the LCA so it doesn't flop around.
Click to expand...

yeah, pretty much the plan, but at 2" it looks like it fits, if I went bigger I would have to mess with the shape
[doublepost=1474379364][/doublepost]So I can get a deal on the laser if I use the size material they stock. Which for 304 stainless steel is only .0598" (16ga) and .1196" (11ga). I was really hoping for something in the middle of those two. The 16 is a bit thinner than I want, but the 11 is way thick. I need like an .080" (14ga) I think. I will see what they can do, but if the price is right, I might just go with the thin, and add ribs or something if I have to.
 
Just out of curiosity what is the thickness of the OEM dust shield?

If you have access to roll a couple beads on .060" 304 or put a couple slight bends in to stiffen it you should be good. If you're planning to burn a lip onto the edge to ensure cooling air goes through the disc and not by the inboard face that will also stiffen it up considerably.

If there is adequate space and you can duplicate the simplified duct @ConeKiller posted from the Evo world you might have new product on your hand. The goofy mustache curls with poor edge distance look like cracks waiting to happen should be addressed but otherwise not a bad idea.
IMG_6627_large.JPG


I'm not smart enough to know how much air is moving below the car in the LCA area but rather than go fog light mounts initially maybe something like...
http://www.velossatechdesign.com/product/2013-2016-focus-st-stage-1-brake-cooling-kit/

Ignore the goofy airbox intake http://www.velossatechdesign.com/product-category/performance/ford-performance/focus-st/

Although since you have a 3D printer replacing fog lights with a custom fit inlet like you were originally planning would be slick. Maybe replace the whole insert? Do you have access to a Faro arm or scanner or the like?
upload_2016-9-20_22-43-31.png

The inlet and caliper duct would direct a lot of air to the brakes and help with cooling.

I don't have any plans to track my car, hell, I'm still learning autox but there is a lot of crossover from aviation to auto racing that make elements of these types of projects a bit easier.
 
In some very high-performance racing applications, I've heard of water injection directly on rotors to cool them down. Sort of like having intercooler spray bars, but for brakes.

Check this out. It's starting around 3:25:
Template public:_media_site_embed_youtube not found. Try rebuilding or reinstalling the s9e/MediaSites add-on.
 
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Redline said:
In some very high-performance racing applications, I've heard of water injection directly on rotors to cool them down. Sort of like having intercooler spray bars, but for brakes.

Check this out. It's starting around 3:25:
Template public:_media_site_embed_youtube not found. Try rebuilding or reinstalling the s9e/MediaSites add-on.
Click to expand...

I think that is probably a bit more than I would need, but cool none the less.

ibcrusn said:
Just out of curiosity what is the thickness of the OEM dust shield?

If you have access to roll a couple beads on .060" 304 or put a couple slight bends in to stiffen it you should be good. If you're planning to burn a lip onto the edge to ensure cooling air goes through the disc and not by the inboard face that will also stiffen it up considerably.

If there is adequate space and you can duplicate the simplified duct @ConeKiller posted from the Evo world you might have new product on your hand. The goofy mustache curls with poor edge distance look like cracks waiting to happen should be addressed but otherwise not a bad idea.

I'm not smart enough to know how much air is moving below the car in the LCA area but rather than go fog light mounts initially maybe something like...
http://www.velossatechdesign.com/product/2013-2016-focus-st-stage-1-brake-cooling-kit/

Ignore the goofy airbox intake http://www.velossatechdesign.com/product-category/performance/ford-performance/focus-st/

Although since you have a 3D printer replacing fog lights with a custom fit inlet like you were originally planning would be slick. Maybe replace the whole insert? Do you have access to a Faro arm or scanner or the like?
View attachment 3880

The inlet and caliper duct would direct a lot of air to the brakes and help with cooling.

I don't have any plans to track my car, hell, I'm still learning autox but there is a lot of crossover from aviation to auto racing that make elements of these types of projects a bit easier.
Click to expand...

The mustache parts are neat, I like the idea of a full dust shield just because of the fact that I am keeping the car DD. I dont have a bead roller, but if the material is to thin, I will just weld a bead around the outside to add strength.

Right now Im working on the front, but when it comes time to do the rear, ducts like that are on my radar. Just havent really looked into them at all yet.

Im curious how the pressure zones under the car would be and what would be the optimal position for something like those.
 
You have a DC or AC/DC TIG machine?

Pressure zones and obviously removal for northern winters.
 
I also hope to see someone here come up with a kit for our cars, as much as I would love to have the direct bolt on kit from mazdaspeed racing, $600 makes it questionable. I have been having issues of heating up my pads immensely on some of the tighter tracks and would love to have a proper cooling duct system. I have looked into the ones for ST's and although our LCA's look identical their kit just aims at the back of the rotor. I wouldn't mind seeing something like Mazdaspeed kit or Evo duct at more of a DIY price. Wish I could contribute more research wise but currently unable to without a place to do so.
 
Bimmertech said:
I also hope to see someone here come up with a kit for our cars, as much as I would love to have the direct bolt on kit from mazdaspeed racing, $600 makes it questionable. I have been having issues of heating up my pads immensely on some of the tighter tracks and would love to have a proper cooling duct system. I have looked into the ones for ST's and although our LCA's look identical their kit just aims at the back of the rotor. I wouldn't mind seeing something like Mazdaspeed kit or Evo duct at more of a DIY price. Wish I could contribute more research wise but currently unable to without a place to do so.
Click to expand...
I'm working on something. Not sure if it will be practical to make for people or not, but if nothing else I will release all my design notes.

Sent from my SM-G900V using Tapatalk
 
Can someone post pictures of the mazdaspeed ones for those of us without access?

Ken whatever you come up with the air needs to be directed into the center of the rotor where the air intake is.
 
Easter Bunny said:
Can someone post pictures of the mazdaspeed ones for those of us without access?

Ken whatever you come up with the air needs to be directed into the center of the rotor where the air intake is.
Click to expand...
Unless someone can track down older pics the only o es currently on Mazda Motorsports website are one ones that fit the Miata.
 
On our 2015 Mazda 3 which is raced in the SCCA we ran 3 inch ducting from the foglights and down the LCA. We used some large clamps to oval the hose to keep it clear of the CV boot and it has been working great.
 
Easter Bunny said:
Can someone post pictures of the mazdaspeed ones for those of us without access?

Ken whatever you come up with the air needs to be directed into the center of the rotor where the air intake is.
Click to expand...
The way I have it planned right now the whole 2" hose will go to the center of the rotor. Should get great flow if I can figure out the mounting upfront

Sent from my SM-G900V using Tapatalk
 
Added to my personal build thread, but I wanted to update this thread in case anyone came across it. Managed to find some time to fit my new dust shied. Just a few tweaks and some spacers and it should be good to go. Have to pick up some correct hardware too. Next up is to order the hose, and the biggest issue is going to be the fog light ducting. People seem to want crazy money for fog light housings.

20170318_115412.jpg
 
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Ever thought about 3D printing some custom brake ducts?
 
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