Performance Pack Brembo Brake Conversion

[boom boom]

I stumbled into a pair of S550 Brembo takeoffs for a song and that got this ball rolling. I think you can normally find them for $400 or so. These were basically brand new takeoffs that had a few installation chips. Junkyard knuckles allowed me to do all of this while keeping the car on the road. Here's the rundown and the pictures.

Parts List:
OEM '03+ knuckles modified for Mustang brakes
2013 G500 rotor with center bore enlarged .026"
2015+ OEM Brembo Calipers
StopTech 950-61003 Brake Hoses (a buddy had these on the shelf so they were free and likely there are better options)
Dorman 13940 Banjo Bolts

The coolest part of this is you can use any OEM or aftermarket mustang brake package that uses the S197 rotor offset.

https://lh3.googleusercontent.com/DppXYzZSHEDpdqI0rWrisIk73iZiLK Ahrz1jcZ5_ZukbP9KJUhvPzSdmwX-qNaSMjObgYH0acN0RI4QdlH8oyNfYY GDLkakMoE7Y64F035TRi53aGVWH0XO Jjyeg3DU1S09OAsNt2lQ=w2400

[boom boom]

I grabbed (3) Panther knuckles and (1) '07 mustang spindle from the junkyard. The mustang spindle needs the iron caliper bracket because I used it to mock up for the knuckle mods. While the mustang spindle was assembled I welded the caliper bracket to the rotor. The center bore had to be enlarged .026" to fit on the panther hub. This would be my jig for all the modifications to the panther knuckles.


https://lh3.googleusercontent.com/HGpzHFBfVGKKulLFNlQIEmBXN6HOUy HsT7AfiIetXq8JQGcGEgQvVRArtDSo 2g7BzAsBAw7u8uEXc3-aGKWcvOPmMdqV2D8QSg0cfXs5xDlYN horc-lBeeHDEQgLsCgsIO1X0EmRrpo=w240 0

[boom boom]

Next was to modify the panther knuckles. Standard disclaimer- DO NOT TRY THIS AT HOME. BRAKES ARE A LIFE SAFETY SYSTEM AND YOU CAN DIE.

Okay, now that is out of the way. The panther caliper bolts are larger than the mustang and the OEM caliper mounting holes are larger accordingly. However, the panther hub bolts are the same diameter and pitch as the mustang caliper bolts. Further, the hub boss on the panther knuckle is the perfect thickness to use for new caliper bosses. One of the three knuckles is sectioned to supply the material for the modified caliper mounting bosses.

The modified knuckle has the panther caliper bosses removed and the hub bosses are welded in at the right offset and spread using the jig above. The dimensions below tell us that the caliper mounting location must be moved 1.81-1.77= .040" toward the frame.

Sorry, I didn't take any pictures of the knuckles being welded. I gave them to a buddy who is an Aerospace welder to finish. His concerns were twofold, one, to make sure that we use similar alloys for welding and the other was the parts would need truing after welding. More on that below.





Front







Diameter
Height
Thickness
Center Hole Dia


2003 Marauder
12.02
1.77
1.105
2.826


2003 Explorer
12
2.2
1.025
3.2


2003 Mach1/Cobra
12.99
1.72
1.1
2.8


2005 GT
12.43
1.9
1.18
2.8


2008 GT500
13.976
1.81
1.26
2.8


2013 Interceptor
13.858
1.85
1.26
2.682


2013 GT500
14.9
1.81
1.26
2.8


2013 Without Brembo
13.22
1.89
1.18
2.8


2013 Boss
13.98
1.81
1.26
2.8


2015 W/Brembo W/O Shelby
14.96
2.52
1.34
2.8


2015 5.0 4 piston
13.86
2.52
1.26
2.8


2015 2 piston
12.6
2.44
1.18
2.8


2004 CTSV - 6 lug
13.986
1.96
1.26
2.79





https://lh3.googleusercontent.com/ANINM8zuA2ltPkjIPZNonn8UOfGCN8 lpE1e-Ejc4ivDU2JIv9TDJ5ZMMiR_NNOXsIP v6xGrR7oROtEROQMTgxzw0_yaS8qGj nluHOFH37jVphqg2j3gL-UQnP-6Qz6ZgTMPRrnIQw84=w2400

[boom boom]

Once the knuckles were welded, the caliper bosses needed to be trued to the hub boss. I indicated the hub boss to the mill and then made a caouple passes with a face mill to true the caliper bosses to the hub. I decided that it would be best to have the ability to shim the fixed caliper as needed so I took some extra material to match the thickness of some washers I had in the shop. You'll see the shims in pictures later.



https://lh3.googleusercontent.com/wolJlhBpc1QzACb8f0YJlZtGK8kLnz HSQgc408ueb4MDHQgLf0NB3MVuGRpO b3jjd6J1TX7tNNqHALm2GrNoOG9pmo yCAG8as1Or97F9p2XVURFFFnbiEw8z bJQbPBDhofeSGdIdYgw=w2400

[boom boom]

Here they are mocked up and ready to be assembled onto the car.


https://lh3.googleusercontent.com/bkTm_PQArqBl2wTPbZGq0JDoEfNQyr jM3aeqXDpYzH8d29-Z22d81VOud0dHgPCseaCqBzkuY8yw4 MYXBflLGNlODMyvJYf4YgysY6f0UaM E4Qrmccin2br3DXHSDe4tHZ_BACN7i uQ=w2400



https://lh3.googleusercontent.com/lz_6edewQnuylbE-1k0KcTRUY7_73EdTL7J4XfubmOggcu tVNj2ByqHGGDsu-pNe4j4ctq2oC7x1BhNKUVDTVXZr32N ZTvz-EdizoLR3rjcoQGiJf2WXDXWHrGvzxs Sbk9Qz9JO5fao=w2400



https://lh3.googleusercontent.com/0aTMMD_2vK7eMIBKWO_90eUhQO3CtE FuFFqv4CjJI3e-FtZCkTGO-V9XnFtfISPw-orkV_KDeFLa1VGBsKQJS5IJxdh0W2T 0LSDtkKvXZbmPo0R0jH7Cr7Wxv7mXg xIwmPxRa9vxYRY=w2400

[boom boom]

Assembling the knuckles onto the car is no different than OEM. I used the hoses mentioned on the first post and they came with brackets that were easily modified so that mounted using the stock location. I will modify this later because the bracket holds the hose and not the fitting which leaves some room for the hard line to move just a little. In these pictures you can see the shims in place so that I can move the fixed caliper inboard or outboard as necessary.


https://lh3.googleusercontent.com/znc6HxCRHu0zkyQILJSNt8aLfqBkrk 3BLytPzkXEhgXHKhV9aHLR12XXlgyv job4WfeS6u-Kv11pD7xuj6e8Ouh8m7H42LhCRyRJQ xWPM5fkhY-BaSST8qeeHKhXrv5rHR-u7tWs9OU=w2400


https://lh3.googleusercontent.com/lR0icB7Ge4NR7eijUAQBec-PVkurO2oZlMjNzeqM5uH-LkfsnesxZu_vvozcgmvWAxBqbvVaOa TuZl6CAaKCz4kBAvzntnUL11kmSfCR NkDa81YMEydgcx212YJlNoQ5DvD7W8-Lczg=w2400



https://lh3.googleusercontent.com/-GtJiCeUDEfKoeE3YFjP1wUlSKbapu1 jDGLsEEkWPjk9yfLPpACOYpoGpzuZ5 3GJ9ddIbp7oZYzzXkYvlRzS6bGy646 iUN8zqDYxhw8e7XdS-e64qik10wypvOTOdaQDxj3eH_8nCfk =w2400

[boom boom]

Here is the complete assembly. The caliper can probably be moved 1/16" toward the hub, but I will leave that for the mod1 version.


https://lh3.googleusercontent.com/UyLX59K6otP9Xqo_H3eoVgxePUcwWz LRzBnfDuZ5BKmM642VuyMFJ9SPFoEF Fczf89vhtP_KJZy6SZqU5R-9OToEQAlHiX1k6pBN-xVxb18p9pUlY5qSkaPF3qZpOUnu_Jc AzNN8t-c=w2400

https://lh3.googleusercontent.com/n2KBtYH8_zJG1h4quMdnfiAwwJ0jrX _ePRRJYRzaUiFaLroGXaDs7ffG5tM3 SF0VIpAFuHC_gTTSO7sFz_E-wiRhx8HpnDLX55K2dleC-bC0kWYaC9hr_AJYkgVHHJKWeIGxwsB Yi4k=w2400

[boom boom]

And finally the wheel mounted- please ignore the dirty car. Here is where things went sideways. I had planned to use a set of (4) rear PP1 wheels, but they need too much spacer because of the lesser rotor offset. The front wheel sticks out way past the fender and it looks ridiculous. So I was dead in the water. I at least had a spare B302S wheel in the shop so I was able to check fitment with reasonably close offset and it is fantastic, just barely past the fender lip. I may try to get a set of boss wheels together in the meantime, but I'm now on the hunt for a set of four oem forged 20" GT500 rear wheels because they are 50mm offset and will clear these brakes.


https://lh3.googleusercontent.com/FOm3maCoY_5XFeDmI-U-JYJFYSrI446Y88irrQXfsqYfJru7ZX LffmI012GH_W8FOlzJfvfEJzkkgykW 5OMIzv28qLadNUCKyaC98tmnWKUyyy x9owKw8IIsee4l3I2JIndooKI9hiI= w2400

[musclemerc]

Nicely done!

[BigCars4Ever]

This obviously will not fit inside the stock wheels.:)

[boom boom]

Nicely done!

Thanks


This obviously will not fit inside the stock wheels.:)

Not a chance, but there is hope... Because this now uses mustang mounting locations you can use any mustang brake that fits the 05-14 cars. I wish I had the the Boss302 Brembos with 14" rotor to check but I don't have access to them. I suspect that they may fit under the stock wheel with a spacer. To that end, I didn't want to leave the car on the stands so I put on a set of new takeoff S197 aluminum floating calipers until I can get the wheels I want. One big note, the piston area is smaller on the mustang caliper so the pedal feels firmer, but it definitely shifts the brake bias a little and is something everyone should be aware of.




Piston Area (one side of caliper)


03-04 MM: 5.67 in^2


05-14 GT: 4.49 in^2


07-12 GT500: 4.29 in^2


13-14 GT500: 4.27 in^2


2015 GT PP: 4.23 in^2



Making some general assumptions for the sake of comparison this gives you an idea of the bias changes.




https://www.tceperformanceproducts.com/bias-calculator/


Front
Rear
Bias


2003 MM
2003 MM
0.667


2013 Boss
2013 Boss
0.691


2015 Brembo
2015 Brembo
0.68


2013 Boss
2003 MM
0.659


2015 Brembo
2003 MM
0.706





So long story short I can now swap calipers, rotors, and wheels in about an hour or two and go from 2-piston floating 12", to 4-piston fixed 14", to 6-piston fixed 15" with a quick pressure bleed and change the wheels to match. Sorry I don't have a better picture, I'll grab one later, but this is the mustang 2-piston floating caliper on the same knuckle.


https://lh3.googleusercontent.com/Uljsmnvx9LUFj_ufUFgU_IwaF5WTuv W_ZtpM4WVXenPXmR4ewgBBxvQfJhVH Cnb3VZjKhyUgqYiHM-YtLLLjY7Pc3hwhHFR9oi3rciBMtGQa aamkhq3oaqLQJPeO9HfgoZMAnnGpt5 c=w2400

[ChiTownMaraud3r]

Very cool. Although will be hard to keep the wheel in the fender like you're finding. The s550 uses a thicker rotor.

Another interesting thing, would be to try the budget big brake kit, with Z06 calipers and 2013 GT500 rotors. There was a guy with a Lincoln trying this, he used 2012 14" rotors and the pads were sticking up too much with too little sweep area...the 13/14 uses a 15" rotor with same other dimensions. Of course this too would require aftermarket/larger wheels.

[hotford]

very nicely done!!

[hotford]

any updates with wheel set up, final costs etc....

[justbob]

Or what about this from last year?

https://www.mercurymarauder.net/forums/showthread.php?108863-Mustang-S550-IRS&

Sent from my iPhone using Tapatalk Pro

[boom boom]

Thanks for the bump. I have been very happy with this setup. In the winter I put the GT 2 piston brakes back on and run whatever garbage wheels I have around. Right now it is a beat up set of PP1 wheels. The PP1 wheel will not clear the brembo caliper without a spacer so the summer setup is the brembo 6 piston with Boss 302S Laguna Seca Wheels. The wheels to look for are any wheels that fit the 2013 GT500 PP. I keep looking for a reasonably priced set of '13 GT500 PP wheels but haven't found a set any closer than Philly.

The GT 2 Piston floaters feel better than the stock brakes ever did on either the 300A or my '03 CV. The pedal is firmer due to the smaller piston area and the bias is more even. I'm very happy with them and prefer a firmer pedal feel. They also fit the stock wheels.

The 6 piston brembos are eye opening. I'm extremely happy with them save for the bias. With the stock rears the bias is too much forward and I'll want to address that at some point. Hopefully with the IRS upgrade that I started last summer, which is waiting patiently in the garage. I had to set it aside after we had multiple deaths in the family, I started a full gut remodel on a family house in the fall, and a new baby a month ago. Hoping to be back on the IRS this summer when the house is done..

Here are my brake bias numbers using TCE's calculator.




https://www.tceperformanceproducts.com/bias-calculator/



Front
Rear
Bias


2003 MM
2003 MM
0.667


2005 GT
2003 MM
0.639


2013 Boss
2013 Boss
0.691


2015 Brembo
2015 Brembo
0.68


2013 Boss
2003 MM
0.659


2015 Brembo
2003 MM
0.706


Aero6
2003 MM
0.754


FNLS6
2003 MM
0.704



And here's a quick picture I just snapped in the driveway.

https://lh3.googleusercontent.com/mMXKFVCLViAJpPp3sQ0P_HK2-Y9KALzGCI2o06w-R4SX61JW2FeqYTT-UrN0ecM4-YRtXghf0upE9cJkXWxsxDFmcTslgRs hSZlM1ARuiWA0hCsK-1VBAkWcrlvukoUNInCDnUhFMjA=w24 00