BrakeUpgrade

After lots of research, some great advice, and some good luck, I decided to upgrade my 911 "S" brakes. The perennial favorite was the 930 upgrade. More stopping power than most of us will ever need at a cost of over $3k. With the 930 upgrade, custom front rotors are required at $700.00 a pair, the rear calipers must be machined to fit the control arms, and the master cylinder must be changed. For my 2500 pound car, my power, and expected track use, I decided to go with Boxster monoblocks and Carrera drilled rotors on the front, and Carrera "M" calipers with Carrera drilled rotors on the rear. After it was all said and done, the upgrade, with pads, cost just over $1k. The benefits, as I see them, other than increased brake performance, are use of: stock rotors, existing master cylinder, and 16" Fuchs.

This is the front set up. Loosen (not to leaking point) the hard brake line at the caliper, then remove two bolts holding caliper to the spindle. Now remove brake line and have a coffee can ready to catch a little brake fluid.
Rotors are retained by 5 bolts. I removed the nuts with the impact wrench before removing hub.
Remove dust cap, retaining nut, and related hardware. Slide hub and rotor assembly off of the spindle. Check all wheel bearings and the rear seal, as now is the time to replace those if needed. Replace the dust cap just enough to stay on. This helps keep dirt out during the next step. Remove Dust shield.

Boxster Monoblock caliper with 36/40 pistons weigh in at 6lbs. with mounting hardware and pads. The '77 calipers with pads were 10lbs.

Here is the kit for mounting the Monoblock to the 911. Very nice work from David Bouzaglou @ TRE Motorsports. Shamless plug: David was very helpful notwithstanding the fact that he only sold me the kit.

Front Pad difference.

Front Rotor difference. Notice the difference in thickness.

Front upgrade finished. The only modifications are removal of the dust shield and the hard line needs to be reformed to feed the new caliper.

Here is the rear set up. Again loosen the hard line to the caliper, then remove mounting bolts. The lower 19 mm bolt is a bit of a pain, but it will come out. Use a 3/8 drive with 19mm to break the bolt from the top then remove the bolt with flare nut or closed wrench.Remove the two screws that retain the rotor, and then release the safety brake.

Rear Rotor difference.

Here are the Carrera Rear Calipers ready for new o-rings and dust boots.

A little compressed air and the pistons pop out. Clean the cylinder and piston and thoroughly blow all fluids from caliper. Install the new o-ring. A little Sly-glyd on the o-ring and the piston should slide right in. Carefully snap dust boot over the piston until it locks in the channel. DO NOT MIX UP THE PISTONS, THEY MUST STAY IN THE SAME CYLINDERS.

Here is the rear upgrade finished. Everything bolted right up.

Final step is bleeding the brakes. Last flush was with ATE Blue, so this time its Gold. By the way, don't let anyone tell you that there is a difference between the two, because there isn't !!!

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	This is the front set up. Loosen (not to leaking point) the hard brake line at the caliper, then remove two bolts holding caliper to the spindle. Now remove brake line and have a coffee can ready to catch a little brake fluid. Rotors are retained by 5 bolts. I removed the nuts with the impact wrench before removing hub. Remove dust cap, retaining nut, and related hardware. Slide hub and rotor assembly off of the spindle. Check all wheel bearings and the rear seal, as now is the time to replace those if needed. Replace the dust cap just enough to stay on. This helps keep dirt out during the next step. Remove Dust shield.
	Boxster Monoblock caliper with 36/40 pistons weigh in at 6lbs. with mounting hardware and pads. The '77 calipers with pads were 10lbs.
	Here is the kit for mounting the Monoblock to the 911. Very nice work from David Bouzaglou @ TRE Motorsports. Shamless plug: David was very helpful notwithstanding the fact that he only sold me the kit.
	Front Pad difference.
	Front Rotor difference. Notice the difference in thickness.
	Front upgrade finished. The only modifications are removal of the dust shield and the hard line needs to be reformed to feed the new caliper.

	Here is the rear set up. Again loosen the hard line to the caliper, then remove mounting bolts. The lower 19 mm bolt is a bit of a pain, but it will come out. Use a 3/8 drive with 19mm to break the bolt from the top then remove the bolt with flare nut or closed wrench.Remove the two screws that retain the rotor, and then release the safety brake.
	Rear Rotor difference.
	Here are the Carrera Rear Calipers ready for new o-rings and dust boots.
	A little compressed air and the pistons pop out. Clean the cylinder and piston and thoroughly blow all fluids from caliper. Install the new o-ring. A little Sly-glyd on the o-ring and the piston should slide right in. Carefully snap dust boot over the piston until it locks in the channel. DO NOT MIX UP THE PISTONS, THEY MUST STAY IN THE SAME CYLINDERS.
	Here is the rear upgrade finished. Everything bolted right up.