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Author Topic: DIY Self drilled Brembo rotors  (Read 9349 times)

April 29, 2012, 10:07:02 pm

1.9aaz

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DIY Self drilled Brembo rotors
« on: April 29, 2012, 10:07:02 pm »
Hey guys,

Thought I would share my experience. I have been having braking issues with my AAZ rabbit swap. (too damn fast!) Rotors warping to hell/brake fade. I decided to try something I have always been curious about, drilling rotors. I designed the pattern on Photoshop and taped it to the rotor. I used a punch to mark the hole centers. Using a 1/8'' drill bit I drilled the first hole and finished off the recess with a 1/4''. I did this all with a hand drill and kept it as close to 90 degrees as possible. I threw them on the brake lathe and grabbed a block and sandpaper to remove the burs on the hole edges.

When all was said and done, I couldn't be happier with the results. I have an 85 911 I am going to try this on next. Don't be afraid to give it a whirl! Its a pretty painless process and the benefits are very noticeable.




Reply #1April 29, 2012, 10:13:58 pm

zukgod1

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Re: Re: DIY Self drilled Brembo rotors
« Reply #1 on: April 29, 2012, 10:13:58 pm »
I've soon this a few times a well. Always had good results.

All I would suggest to people doing this is try to stay at least 1/4" from the edge to prevent cracking.



Send from my mobile thingy. Never while driving though.
dan

99 Golf TDI (now CNG powered) , 82 TD Caddy

Reply #2April 30, 2012, 01:19:05 am

cyrus #1

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Re: DIY Self drilled Brembo rotors
« Reply #2 on: April 30, 2012, 01:19:05 am »
All I would suggest to people doing this is try to stay at least 1/4" from the edge to prevent cracking.

Also, be sure to create a nice chamfer around the edge of the hole to relieve stress.  The OP has done a good job, judging by the picture.
Cody

2002 Jetta TDI
2000 Jetta TDI - R.I.P.
1990 Jetta 8v-Eventually to be 1.6TD

Reply #3April 30, 2012, 02:28:47 am

mystery3

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Re: DIY Self drilled Brembo rotors
« Reply #3 on: April 30, 2012, 02:28:47 am »
How big are your rotors front and rear? This really isn't necessary on a 2000lb vehicle with unless you've spent a lot of time and money on brake upgrading already?

Reply #4May 01, 2012, 04:08:04 pm

rabbitman

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Re: DIY Self drilled Brembo rotors
« Reply #4 on: May 01, 2012, 04:08:04 pm »
Are they vented or solid rotors?
'82 Rabbit, I put on a euro vnt-15, 2.25" DP, 2.5" exhaust, the result.....it whistled.

I removed the turbo, made a toilet bowl 2.5" DP, the result....it was deafening. Now it has a homemade muffler up front and a thrush in the rear, the result.....less loud.
Watch: AGENDA, GRINDING AMERICA DOWN

Reply #5May 01, 2012, 06:52:27 pm

1.9aaz

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Re: DIY Self drilled Brembo rotors
« Reply #5 on: May 01, 2012, 06:52:27 pm »
Hey guys,

They are 9.5'' solid rotors. My issue was my heavy foot braking after a "spirited" run. Sometimes stop signs/turns come a little quicker then expected with 28PSI :P The rotors would constantly get heat soaked and fade. I would also warp them quite frequently.  I was in a DIY mood and made some RS door panels too! Came out great!




Reply #6May 01, 2012, 06:55:32 pm

1.9aaz

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Re: DIY Self drilled Brembo rotors
« Reply #6 on: May 01, 2012, 06:55:32 pm »
Here is a pic of the power plant herself.


Reply #7May 01, 2012, 07:41:21 pm

camboscams

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Re: DIY Self drilled Brembo rotors
« Reply #7 on: May 01, 2012, 07:41:21 pm »
This is wildly off topic, but what radiator and intercooler are you running. That's the best setup I've seen on here! Do you ever have any overheating problems with the smaller volume? Hats off to you my friend
81' White 1.6l Rabbit 4dr Holseted
72' Ford F-250 390cid
2014 JSW 2.0L TDI Stg 2, CP3 HPFP

Reply #8May 01, 2012, 11:03:07 pm

1.9aaz

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Re: DIY Self drilled Brembo rotors
« Reply #8 on: May 01, 2012, 11:03:07 pm »
Thanks! I own/operate a repair shop and do fab work as a hobby after hours. I have boosted a far share of cars in my day and really enjoy induction/exhaust work/design. The intercooler is a Mazda OEM cooler I modified to the correct outlet orientation. The radiator is also a modified OEM design. It is intended for a Mini. I have a remote oil cooler (removed the stock one) and also have a secondary cooling "finned tube" on the firewall to make up for the reduced size. I am running a custom orifice in the coolant neck in place of a thermostat. This I machined to the optimal "flow" for the cooling characteristics of my setup. I change the orifice size for summer/winter.

Reply #9May 13, 2012, 07:33:47 pm

belchfire

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Re: DIY Self drilled Brembo rotors
« Reply #9 on: May 13, 2012, 07:33:47 pm »
Yeah, layout can be fun trying to keep things symmetrical, balance and all. Chamfer may be good for stress but I thought that the sharp edges helped to de-glaze the pucks. 
The Owl of Minerva flies at dusk
'81 rabbit pick up  1.6 turbo diesel  SVO

Reply #10May 14, 2012, 07:30:17 am

veector

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Re: DIY Self drilled Brembo rotors
« Reply #10 on: May 14, 2012, 07:30:17 am »
Why not upgrade to vented rotors?  I have stock vented rotors up from and 200mm drums out back, the mk1 stops on a dime even from speeds over 120km/h
1981 Jetta D
1997 Jetta TD

Reply #11May 15, 2012, 09:40:30 pm

Blocksmith

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Re: DIY Self drilled Brembo rotors
« Reply #11 on: May 15, 2012, 09:40:30 pm »
Why not upgrade to vented rotors?  I have stock vented rotors up from and 200mm drums out back, the mk1 stops on a dime even from speeds over 120km/h
three letters:  D I Y   ;D
Good job, OP. I just bought a drill press today for other stuff I have planned, but then I saw this, so I'm gonna try it for my dad's Jettas.
Green 83 Rabbit 4dr, 5 speed ACH trans swap, ported 1.6D mech lifter w/ vnt15, na pump w/ gov mod, gasser intake mani, 2.5" exhaust, bilstein sports and cut mk2 springs, ss brake lines, 14" vw bottlecaps

Reply #12May 31, 2012, 08:18:17 pm

Smokey Eddy

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Re: DIY Self drilled Brembo rotors
« Reply #12 on: May 31, 2012, 08:18:17 pm »
Ed Approves!
Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD

Reply #13June 08, 2012, 02:06:12 am

wolf_walker

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Re: DIY Self drilled Brembo rotors
« Reply #13 on: June 08, 2012, 02:06:12 am »
As cool as that is, you are still nuts not to just put good vented rotors on it and good pads.  :)
Many things we do naturally become difficult only when we try to make them intellectual subjects. It is possible to know so much about a subject that you become ignorant.
Mentat Text Two

Reply #14June 08, 2012, 01:53:00 pm

R.O.R-2.0

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Re: DIY Self drilled Brembo rotors
« Reply #14 on: June 08, 2012, 01:53:00 pm »
As cool as that is, you are still nuts not to just put good vented rotors on it and good pads.  :)


you can tell the difference between vented and solid rotors. well, i could atleast..

i took the solid disks off my Jetta and threw some old audi coupe GT vented disks, and it stopped better..
92 Jetta GLI - Black, 1.6D w/ GT2056V turbo..
86 GTI - 4 Door, Med Twilight Gray, Tow Machine..
86 Audi Coupe GT - Tornado Red, All Stock.. WRECKED.
89 Toyota 4Runner - Dark Grey Metallic, LIFTED!

Turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster.