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Brake upgrades part 2: developing a 2 piece 11" brake rotor BBK

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    Brake upgrades part 2: developing a 2 piece 11" brake rotor BBK

    So to continue in this series and not get anybody confused with the other brake rotor thread, this thread will cover the 11" 2 piece rotor and upgrade path.

    This one will be a lot more involved than the OE size rotor and it will require sourcing out more parts and as a result be little more expensive, but it will allow the BG people to use an 11" rotor with the OEM caliper.

    1: A Kia BG knuckle will have to be used due to it having shorter caliper mounts and making this possible.
    2: The Kia hubs will have to be swapped out for normal BG hubs since they have a larger OD
    3: The lower strut hole on the struts will have to be lengthened vertically or the same thing done to the knuckle, your choice
    4: A bushing made by Ferdi will have to be used to allow the tie rod to be installed upside down to match the height of the one from the original knuckle
    5: The OE caliper will require some grinding to allow the use of the larger rotor

    This may seem like a lot of work but there are a couple of positive aspects of using this knuckle.

    1: The bearing/hub in relation to the strut mounts is higher up by about 1/4-3/8" thus lowering the car a little without affecting your suspension geometry
    2: The ball joint mount is 1/8" lower which again helps with suspension geometry
    3: The obvious one is allowing the use of 11" rotors using a custom caliper bracket

    The pictures below will help explain it all.
    Last edited by KAinjection; 03-15-2015, 07:08 PM.
    92 Mazda MX3 GS> For sale, $1750 OBO
    94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
    "Hold yourself accountable before you are held accountable"
    EV14 330cc@3Bar injector kits available.
    EV14 GT500 injector kits available for the BP. 610cc@3Bar.
    EV14 925cc@3Bar injector kits available
    BP Forged H beam rods available now
    KL Forged H beam rods available now
    K8/KF Forged H beam rods awaiting test fit
    FS Forged H beam rods
    awaiting test fit
    F2 Forged H beam rods awaiting test fit
    FE3 Forged H beam rods coming soon
    Mitsubishi 3.8 MIVEC rods coming soon
    Aluminum CAS/Distributor caps
    BP oil jet eliminators
    EV14 fuel rail spacers
    More stuff coming soon.......

    #2




    92 Mazda MX3 GS> For sale, $1750 OBO
    94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
    "Hold yourself accountable before you are held accountable"
    EV14 330cc@3Bar injector kits available.
    EV14 GT500 injector kits available for the BP. 610cc@3Bar.
    EV14 925cc@3Bar injector kits available
    BP Forged H beam rods available now
    KL Forged H beam rods available now
    K8/KF Forged H beam rods awaiting test fit
    FS Forged H beam rods
    awaiting test fit
    F2 Forged H beam rods awaiting test fit
    FE3 Forged H beam rods coming soon
    Mitsubishi 3.8 MIVEC rods coming soon
    Aluminum CAS/Distributor caps
    BP oil jet eliminators
    EV14 fuel rail spacers
    More stuff coming soon.......

    Comment


      #3
      reserved
      92 Mazda MX3 GS> For sale, $1750 OBO
      94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
      "Hold yourself accountable before you are held accountable"
      EV14 330cc@3Bar injector kits available.
      EV14 GT500 injector kits available for the BP. 610cc@3Bar.
      EV14 925cc@3Bar injector kits available
      BP Forged H beam rods available now
      KL Forged H beam rods available now
      K8/KF Forged H beam rods awaiting test fit
      FS Forged H beam rods
      awaiting test fit
      F2 Forged H beam rods awaiting test fit
      FE3 Forged H beam rods coming soon
      Mitsubishi 3.8 MIVEC rods coming soon
      Aluminum CAS/Distributor caps
      BP oil jet eliminators
      EV14 fuel rail spacers
      More stuff coming soon.......

      Comment


        #4
        reserved2
        92 Mazda MX3 GS> For sale, $1750 OBO
        94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
        "Hold yourself accountable before you are held accountable"
        EV14 330cc@3Bar injector kits available.
        EV14 GT500 injector kits available for the BP. 610cc@3Bar.
        EV14 925cc@3Bar injector kits available
        BP Forged H beam rods available now
        KL Forged H beam rods available now
        K8/KF Forged H beam rods awaiting test fit
        FS Forged H beam rods
        awaiting test fit
        F2 Forged H beam rods awaiting test fit
        FE3 Forged H beam rods coming soon
        Mitsubishi 3.8 MIVEC rods coming soon
        Aluminum CAS/Distributor caps
        BP oil jet eliminators
        EV14 fuel rail spacers
        More stuff coming soon.......

        Comment


          #5
          wow!!! i never realized just how much different that kia spindle was.
          ---Has ClubProtege helped you in someway? show your support by Contributing--- Click Here---

          1992- project FE3..... 313 WHP @ 9.3psi




          I pet my dash when I get into the car..."good car"
          he actually has a mazda tree, parts grow on it

          Comment


            #6
            It would be nice if it was closer to the BG stuff, but what's the fun in bolting something on without modding it?

            I am kinda curious now how some RX-7 calipers would work with this setup....
            Last edited by KAinjection; 03-25-2015, 08:57 PM.
            92 Mazda MX3 GS> For sale, $1750 OBO
            94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
            "Hold yourself accountable before you are held accountable"
            EV14 330cc@3Bar injector kits available.
            EV14 GT500 injector kits available for the BP. 610cc@3Bar.
            EV14 925cc@3Bar injector kits available
            BP Forged H beam rods available now
            KL Forged H beam rods available now
            K8/KF Forged H beam rods awaiting test fit
            FS Forged H beam rods
            awaiting test fit
            F2 Forged H beam rods awaiting test fit
            FE3 Forged H beam rods coming soon
            Mitsubishi 3.8 MIVEC rods coming soon
            Aluminum CAS/Distributor caps
            BP oil jet eliminators
            EV14 fuel rail spacers
            More stuff coming soon.......

            Comment


              #7
              Thats pretty interesting how its set up.

              Comment


                #8
                Is the Kia spindle caliper mounts closer to the axle center than on a BG 323? If the BG 323 spindle could be used you would only need the caliper spacer and possibly the smaller 323 ball joints to mount it. Everything else is interchangeable.

                Comment


                  #9
                  I think they are because when Ferdi made his one off 11" BBK using the knuckle for the 9" brakes, he still had to shave off the end of the mounting ears and the caliper mount holes were right next to each other, vs mine which are at least an 1" apart or more. The Kia mounts are very similar to Miata mounts.
                  Last edited by KAinjection; 03-25-2015, 08:57 PM.
                  92 Mazda MX3 GS> For sale, $1750 OBO
                  94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
                  "Hold yourself accountable before you are held accountable"
                  EV14 330cc@3Bar injector kits available.
                  EV14 GT500 injector kits available for the BP. 610cc@3Bar.
                  EV14 925cc@3Bar injector kits available
                  BP Forged H beam rods available now
                  KL Forged H beam rods available now
                  K8/KF Forged H beam rods awaiting test fit
                  FS Forged H beam rods
                  awaiting test fit
                  F2 Forged H beam rods awaiting test fit
                  FE3 Forged H beam rods coming soon
                  Mitsubishi 3.8 MIVEC rods coming soon
                  Aluminum CAS/Distributor caps
                  BP oil jet eliminators
                  EV14 fuel rail spacers
                  More stuff coming soon.......

                  Comment


                    #10
                    1 small update on the Kia knuckles. Just for fun I stripped a BG and Kia knuckle down and weighed each one on a scale at work. The BG one was 8lb 4oz and the 3 Kia ones I weighed varied from 7lb 10oz down to 7lb 7oz. I took it a step further and shaved all the casting flash off of one, removed the ABS sensor boss, removed all sharp edges and smoothed it all with sanding rolls. After all that I weighed it again and it came out to 6lb 14oz. So i am 2 oz shy of being a 1.5lbs lighter than the BG knuckle. Something to think about for the autoX guys.
                    92 Mazda MX3 GS> For sale, $1750 OBO
                    94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
                    "Hold yourself accountable before you are held accountable"
                    EV14 330cc@3Bar injector kits available.
                    EV14 GT500 injector kits available for the BP. 610cc@3Bar.
                    EV14 925cc@3Bar injector kits available
                    BP Forged H beam rods available now
                    KL Forged H beam rods available now
                    K8/KF Forged H beam rods awaiting test fit
                    FS Forged H beam rods
                    awaiting test fit
                    F2 Forged H beam rods awaiting test fit
                    FE3 Forged H beam rods coming soon
                    Mitsubishi 3.8 MIVEC rods coming soon
                    Aluminum CAS/Distributor caps
                    BP oil jet eliminators
                    EV14 fuel rail spacers
                    More stuff coming soon.......

                    Comment


                      #11
                      I wish the rules allowed me to use non-Mazda knuckles or to be able to modify stock ones Unfortunately I have to use unmodified 323/Protege/MX-3 knuckles.The guys in Street Modified and higher classes could swap them tough.

                      Comment


                        #12
                        Whats that mean for your brake upgrades? the OEM size 2 piece rotors only
                        92 Mazda MX3 GS> For sale, $1750 OBO
                        94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
                        "Hold yourself accountable before you are held accountable"
                        EV14 330cc@3Bar injector kits available.
                        EV14 GT500 injector kits available for the BP. 610cc@3Bar.
                        EV14 925cc@3Bar injector kits available
                        BP Forged H beam rods available now
                        KL Forged H beam rods available now
                        K8/KF Forged H beam rods awaiting test fit
                        FS Forged H beam rods
                        awaiting test fit
                        F2 Forged H beam rods awaiting test fit
                        FE3 Forged H beam rods coming soon
                        Mitsubishi 3.8 MIVEC rods coming soon
                        Aluminum CAS/Distributor caps
                        BP oil jet eliminators
                        EV14 fuel rail spacers
                        More stuff coming soon.......

                        Comment


                          #13
                          Originally posted by 300zxrb26dett View Post
                          Whats that mean for your brake upgrades? the OEM size 2 piece rotors only
                          Or larger.

                          Comment


                            #14
                            If you want to go to the 11.75" then the rotor rings are surprisingly cheap but the hats will have to be redesigned for them, or find a way to run a 949racing miata 11.75" kit.
                            92 Mazda MX3 GS> For sale, $1750 OBO
                            94 Escort wagon--BP swap coming, VF10 Turbo, COP, EVO ECU, 03 ZX2 front end conversion
                            "Hold yourself accountable before you are held accountable"
                            EV14 330cc@3Bar injector kits available.
                            EV14 GT500 injector kits available for the BP. 610cc@3Bar.
                            EV14 925cc@3Bar injector kits available
                            BP Forged H beam rods available now
                            KL Forged H beam rods available now
                            K8/KF Forged H beam rods awaiting test fit
                            FS Forged H beam rods
                            awaiting test fit
                            F2 Forged H beam rods awaiting test fit
                            FE3 Forged H beam rods coming soon
                            Mitsubishi 3.8 MIVEC rods coming soon
                            Aluminum CAS/Distributor caps
                            BP oil jet eliminators
                            EV14 fuel rail spacers
                            More stuff coming soon.......

                            Comment


                              #15
                              I want to keep the diameter to a minimum. The rotor width also has to be the same or bigger than stock which means the smallest rotor from Willwood that will work is a 10.75" rotor (.81" thickness). I've been looking at this one...

                              Rotor No: 160-7097-BK, rotor, rotors, carbon ceramic, carbon ceramic rotors, iron rotors, steel rotors, rotor hats, directional vane, staggered, straight vane, srp drilled, disc rotor, drum rotor, internal parking brake, steel rotors, aluminum rotors, bedding, bedding-in, mounting, mount

                              Comment

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