Leaderboard

Plenty of progress but not much posting of it lately. Plenty of spicy spam below ... --- Rear End --- The used 996 Brembo calipers arrived last week (very nicely packed) and on Friday I picked up the M3 rear rotors (DBA 4000 series) so I could check the fitment before carrying on with anything else. Some findings / notes through the process so far (most of which can be found on the internet but will echo here for completeness): The rear Porsche calipers to get are from 1999-2004 996 (non-turbo), the Boxster S or Cayman S. Part numbers are 996.352.421 and 996.352.422 Piston sizes on the Brembo calipers are ⌀28 and ⌀30 Dust boot part numbers are 20 4872 40 and 20 4872 41 Complete caliper seal kit part number is 143.37009 You need to use M3 rear discs on either 330 or M3 trailing arms and source the appropriate brackets (Rally Road or Creation Motorsport the most common) 330 and M3 parking brake shoes are different widths (20mm on 330 vs 30mm on M3) but the disc drum diameter is the same at ⌀185mm, looks like i can just use my 330 shoes in the M3 disc no problem and upsize them when they wear out The M3 and 330 discs are the same overall height (61mm) but the M3 rotor itself is about 11.5mm further inboard (the 330 parking brake drum protrudes from the disc face, the M3 is basically flat) The dust shield needs to be trimmed for caliper fitment and flattened out to not foul the disc due to the rotor itself moving. I cut slits in mine (330 items) for now to flatten it back in sections, but this does look pretty average. You need to retain the centre of the dust shield if nothing else as the parking brake shoes mount to it. The disc retaining bolt on the 330 vs M3 discs are different, you will need to add this counter-bored hole to the M3 discs to do a nice job of things The specified OEM pads for this caliper are the D738 shape but apparently the D737 can also be used and wipes more of the disc (D738 leaves a ring on the inside where the pad does not wipe apparently) The OEM caliper cross over pipes need to be changed to the opposite ends of the calipers as they mount to the rear on the E46 and to the front on the Porsches.This maintains the correct piston size stagger (rotor passes the smallest piston first). Some other misc measurements which may help somebody for something in the future: Piston size on the OEM 330 rear caliper is ⌀42 Rear disc centre bore is ⌀75mm OEM 330 hub flange is ⌀145mm Thickness of DBA rotor hats (where the disc sits on the hub) is 7mm --- Front End --- I've identified which direction I'll be going now with the front setup. Going to go for a two piece rotor using 356x30mm DBA disc and aluminium top hat. Still might look at getting the Freaky Parts folks to supply the calipers and brackets / hoses etc but will see now as they may not be interested if there is not wider market appeal. The reasons for going this way over the CSL discs are: I don't want cross drilled rotors, which nearly all of the CSL spec items are Call me a snob here but I want front and rear rotors to match So to that end I've been beavering away measuring my 330 king pin's / knuckles along with my wheel inside profile and getting everything modeled up to a reasonable state. More random facts and measurements are as below for the front end based on Renault Megane 275 Trophy R Brembo calipers. Factory Renault uses disc size ⌀340 x 28mm Pad sweep depth of 61mm There are numerous options and from what I can tell the correct part numbers for the calipers are 410116043R & 410010873R The OEM pad part number is 410603303R Calipers use dual ⌀40mm pistons per side Some other misc measurements which may help somebody for something in the future: Piston size on the OEM front 330 caliper is ⌀57 Front disc centre bore is ⌀79mm OEM 330 hub flange is ⌀140mm --- Images --- What you get when you paint the calipers on the car. Factory colour is the grey. The bracket installed, there is the slightest interference with the bolt head for the upper control arm. Literally needs a couple of passes with the file. Trimming the dust shield in line with the bracket mounting face. Test fitting the caliper. Note the slitting of the dust shield so it could easily be flattened out. I will likely trim this to the disc size so you can't see my handiwork here. This is showing the pad sitting slightly away from the hat on the rotor, which is apparently solved using a slightly larger pad. A good illustration of the difference between the M3 (left) and 330 (right) discs. You can clearly see the parking brake drum protruding on the 330 item. Setting up the 'coordinate system' for measurements of the front caliper mounting in relation to hub centre. This is using a laser level and ruler taped onto the hub face which is set level. Here I am running the laser straight along the ruler edge so i can establish exactly where 90 degrees is to it so my measurements are all nice and square. ... then I can establish my 'zero offset' using the ruler measurements. Strange how the laser looks like a chalk line in the pictures An example of measuring the mounting hole positions using this technique. I'd estimate accuracy of +/- maybe 0.5 - 1mm which will be good enough to prototype using the 3D printer, or to validate against known good values from an M3 to see what is the same and what is different etc. Had to cut off the bridging pipes to be able to remove with a proper socket as the flare wrench was making a mess of things. Pistons and dust boots removed ready for some paint stripping and cleanup prior to painting. A couple of shots from the 3D modeling of the front setup. It's not meant to look flashy but represent accuracy where it's needed. I neglected to get pictures of taking the measurements of the inside wheel profile (spokes), but involved the same ruler sitting square and centres on the wheel mounting face then taking 'drop' measurements every 10mm. It worked out really well when you look at the reproduced contour.

I have the same one.

yes.

I recently moved house and after unpacking all the boxes found a present I was given for my 21st birthday by an acquaintance. A crystal model of a 635CSi and it's still in pretty good nick considering my 21st birthday was quite some time ago (hint, last century).

my image South Island 2015 e46 Touring, near Lake Pukaki if I recall correctly. Nikon D3 most likely with a Nikkor 24-70 2.8 and pol filter.