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Cheap, stealthy brake ducts.

RAAMaudio

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#1
Terribly sorry no pics, having a tough time with hosting right now, most are on my phone and cannot get them to load, using my camera now so will get some up as soon as I have a bit of time. This is not a hard mod, does not take a ton of time but then again that can be considered quite different for some, I love modding, used to put in 8 hours at least a day after my job when I was still working.


Air inlet side.
I was working on the under under tray I added to the spliter I am using with open area in the middle that goes into the area where the stock rubber air dam used to be. This made a nice place to tap into so I sealed it up, added some 2" ABS tubing outlets, had it all sorted out but did not want to install the under tray yet due to a ton of recent mods I need to do test runs to ensure no leaks, etc.....I was installing the stock rubber air damn for now and realized I could just cut some ABS sheet to fit and then had really good inlets for when not running the under tray. It took less than an hour and less than $2 worth of ABS sheet.

You do not need a splitter, undertray, etc to create some great cheap air inlets just trap some of the air that hits the stock rubber air damn as it goes off to the side of the car. When I get some pics up you will see it is a pretty simple and low cost way to do this, just takes a little time, you can do it and not even pull the bumper cover off.

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You can tailor the rotor side to fit your rotors, etc...what I am doing is using 2" copper tubing and some sheet as can solder that easily enough, my welder is in storage, I will make new ones when I have access to my tools. The copper tube will fit through a plate mounted to the stock backing plate mount locations, no need to try to make it cover the whole back of the rotor opening as the WW BBK top hats have big holes between the mounts to the rotor so most of the air would just blow out and do little good. I decided to make the tubing go into the backs of the rotor opening as far as possible, seal up the ends and then open up the side, add some flanges, blow all the air towards the fins inside the rotors which are designed to pull air through.

By doing it this way it will maximize the cooling effect and balance it out from front to rear face of the rotor which is far better than most brake duct setups which can result in uneven heating the rotor areas, not a good thing.

I will also add a port to blow air onto the wheel bearings, have not figured that out yet but it should be pretty simple to make.

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I ordered some 2" brake duct hose, 6 ft, 4 was enough but they sold either 3 or 6' lengths, $58.99
1' copper 2" tubing, $15
Copper sheet, $8
Good hose clamps, $8
2" ABS pipe, 2 ft, $3 (1.2 ft would be enough)
Pop rivets, adhesive, $4
ABS sheet, $1

Total $100 or so, if I still had my shop I would of used aluminum for the tubing, total cost would of dropped to around $80.

--------------

NOTES:

2" hose, tubing etc due to 3" I had on hand was simple to large to use as effectively, this setup will have a lot of air pressure to speed up the flow and more than enough air going directly into the middle of the rotors, it will be more effective than any other brake cooling I have ever bought.

When not needed some foam insulation can be pressed into the opening, pulled out when needed, barely weighs anything and cheap.
 


Siestarider

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#2
Sounds great, but the pics are key to understanding your account, I only imagine I understand.

For myself, the CMB ducts I am using now appear to work so well I am staying on stock brakes. Just picked up new OEM pads too. Next track day (May 28) I will force the ABS to engage at end of back straight at PBIR, that should be the ultimate track test of stock brakes. I just wish I could mount lighter rotors without going whole new setup.
 


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RAAMaudio

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Thread Starter #3
Not much into posting photos as it is but when having trouble doing so it is very frustrating when I come up with ways to make cool stuff that works for cheap and want to share it:(

In the past on other vehicles I have just wire tied brake duct hose to blow air the best I could get it where needed when in a pinch and it helped a huge amount, The CMB units are not optimal in design but far better than nothing as well which you have already benefited from.

If you get me the exact specs on the stock rotor I will see if I can figure out a two piece setup you could run.

-Rotor diameter
-Rotor width
-Rotor hat(what it is called in two piece setups, what the studs and hub mount through and the rotor is offset from) offset, how far back is the rotor.
-Hat internal and external diameter
-Hat face that sits on the hub flange thickness
-Anything else you find that might be of interest in this

When I did the 4 piston rear BBK setup on the car I found hats what were perfect in every way except rotor offset was to far back, I had a machine shop remove just enough to get it all lined up which could be required depending on what WW has to offer.

Once you get the hat figured out and can just bolt on new rotors as needed and their are some very cheap WW ones that are quite good though I prefer to run the GT series rotors.
 


Siestarider

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#4
10-4, I will gather the data for both front and rear rotors. Probably have to pull mine off and measure, not likely all those dimensions are readily available but I will find out. It would be awesome for community to have light rotor options.
 


Siestarider

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#5
Front Rotor
OD 278 mm
Thickness 23 mm
Hub 63.5 mm
Hat outer face offset from rotor face 21 mm
Hat OD 146.2 mm
Hat ID ?

Rear
OD 252.7 mm
Thickness 10.1 mm
Hat OD 165 mm
Hub 63.6 mm
Hat outer face offset from rotor face 22.9 mm
Hat ID ?

Found these dimensions on Autozone site. Missing the hat ID for both. thought maybe I could find separate hub OD's and get them that way, no joy.
 


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RAAMaudio

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Thread Starter #6
Thanks, I will have to look it all over and see what I can come up with to help for stock brakes:)

For the inlet side please take a look at the pics and use your imagination a bit as it is not easy to post pics and sometimes even post at all using my cell phone data...

Stock "undertray" that attaches to front bumper cover and the stock air dam attaches to, this one is modded in the middle to sit flat against the lowered DHM race IC, that area has nothing to do with the brake ducts. I first used self taping screws to hold it all together and a heat gun for form APS sheet to seal up the front and stiffen things up. I also cut about a 35 degree angle on the 1.5" ABS tubing so it fit pretty tight against the slope of the leading edge of the stock piece.

I used a heat gun to form the stock sections to the ABS as well then once set put in aluminum rivets to replace the screws and used Goop RV sealant which I find far stickier, firmer and faster setting than silicone to seal all air gaps.



The ABS tube was opened up as much as I could and rounded over edges to allow as much air to flow into the tube from the side of it. You can see the rivets and RV Goop in place as well as the ABS sheet that ensures air flows into it as diverted from going under the car towards the sides of it by the stock air dam.



Moving back a bit so you can see the whole thing a bit better. the ABS sheet is around 8" long, heated and bent lip to catch more airflow.

I am sure this design will pull in a lot of air.



After I finished this up I removed the stock air dam and installed the alumalite undertray, now the gap under the higher section in the middle bottom of the bumper cover is sealed up so all the air flowing to it, 3/4x30+ inches or so, a lot of air forced through the ABS tubing the 2" brake duct hose will attach to.

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Sorry for the sucky pics and less that show car design, this is about cooling brakes and the parts will not be seen by anybody anyway though it is very strong, very low weight and very cheap to do.

Originally I was going to use the stock fog light locations and bought subwoofer ports to fit there but I realized with the undertray I had built there was this great air channel going nowhere so I decided to tap into it and also figured out it could be used with out an undertray or with so I did both.

I forgot to post pics with the undertray on but a bit of foam tape and imagination, pretty easy to see how it works out:)

------------------

I have been down a few days, hope to get back to it tomorrow, ruptured a vessel in my right eye, been taking car of that instead.
 


Siestarider

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#7
Really creative and tidy inlets, stealthy too. I believe you are right about getting air that way, my manometer testing indicates +2" in that area.

I also use Goop, and agree its superior to RTV. It also stays good longer in capped tube, I have had it last years after opening.

Have to laugh at myself, all that work I did to make brake duct inlets next to fog lights stealthy and black, noticed after whole system was mounted I forgot to spray inside, so the insides of the white pvc pipes I glassed in jump out if you look. You obviously thought a little further ahead than I did. Nice job and great alternative to the way I did it.
 


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#8
Really creative and tidy inlets, stealthy too. I believe you are right about getting air that way, my manometer testing indicates +2" in that area.

I also use Goop, and agree its superior to RTV. It also stays good longer in capped tube, I have had it last years after opening.

Have to laugh at myself, all that work I did to make brake duct inlets next to fog lights stealthy and black, noticed after whole system was mounted I forgot to spray inside, so the insides of the white pvc pipes I glassed in jump out if you look. You obviously thought a little further ahead than I did. Nice job and great alternative to the way I did it.
Currently designing a similar thing.

Sent from my SM-G900I using Tapatalk
 


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RAAMaudio

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Thread Starter #9
Thanks:)

I did not start out with this idea, I was going to use NACA ducts but was having a bit of fitment issue with 3" hose and went looking for 2" NACA units but could not find any then thought about the 1.5" ABS pipe left over from remodeling my daughters bathrooms, happens to be 2" outside diameter, a bit less flow than thinner wall stuff or NACA ducts perhaps but with that much pressure on the area I doubt flow will be a problem.

Then I did the ducts onto the stock "undertray" but did not want to put the spiltter/undertray on as still in shakedown mode on the new turbo so put the stock air dam bits on and it just stood out as a very simple way to capture the air their. It took hardly any time to do it as I just flipped the bumper cover over, traced a pattern, cut with sheet metal shears, trimmed, etc....stock bolts for the undertray to bumper hold it in place.

I did design in a tab I was going to bend up and put a screw through into the rubber air dam but just cut a slot and slid it in instead so it is supportd on the rear side, works great.
 


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RAAMaudio

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Thread Starter #10
After reading all the posts about undertrays, etc....I decided to make mine shorter and cut if off at the front of the wheel well openings, makes getting to everything far easier, can even change the oil with it on. I will make a vertical lip to replace the stock rubber unit or mod the rubber parts and use them then buy new ones for off season use when I want to have the spliter off the car.

I need to trim back a few mods as my car is not to the point where it would have to run in a super high speed class in TT events where the cars are not really street cars any longer so this saves a few points buy not running a full length undertray.
 


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RAAMaudio

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Thread Starter #11
After reading all the posts about undertrays, etc....I decided to make mine shorter and cut if off at the front of the wheel well openings, makes getting to everything far easier, can even change the oil with it on. I will make a vertical lip to replace the stock rubber unit or mod the rubber parts and use them then buy new ones for off season use when I want to have the spliter off the car.

I need to trim back a few mods as my car is not to the point where it would have to run in a super high speed class in TT events where the cars are not really street cars any longer so this saves a few points buy not running a full length undertray.
 


Siestarider

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#12
I also bought 3" NACA ducts for undertray experiments, Could not find 2" either. Played with test fitting them to undertray, not much room in real world. Then piped brake ducts and no room left. So cut holes in hood, but so far they are not adequate for Fla heat tracking, still have to fall back on trusty heater.

Had to put aeromods and cooling on back burner, need to decide what to do with suspension/ride height. Finally getting good enough on track to at least suspect something, maybe even have a clue.

Any thoughts about those way stiffer Swifts and BC coils?
 


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RAAMaudio

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Thread Starter #13
Since I have the radiator, oil cooler, ducting, etc about as maxed out as can be done and now a bit of a vented hood cooling should not be an issue.

The car is on the stiff side but I also have all the urethane bushings so it was pretty stiff already but now it is a bit stiffer but reacts more smoothly. Not sure I would want this setup in some areas of the country but out in the west most roads are pretty good. I have the dampers on 22 out of 32, front springs 8k, rear 7k, I need to adjust the rear dampers down a bit and hopefully it will smooth things out really well.

Stock front bar, urethane bushings, no rear bar, corners very flat, very fast transitions, very good feedback, I might have to go run an autocross when my right eye clears up a bit, just had laser retinopexy surgery done less than an hour ago and drove home. Surgery was fast but not much fun, ouch!

Now I feel like I took a hard punch in the eye, headache, time for some Laganitus beer, which I am enjoying, really helps with the pain:)
 


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