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Thread: Performance Pack Brembo Brake Conversion

  1. #1
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    Performance Pack Brembo Brake Conversion

    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.


  2. #2
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    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.



  3. #3
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    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




  4. #4
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    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.




  5. #5
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    Here they are mocked up and ready to be assembled onto the car.











  6. #6
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    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.










  7. #7
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    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.





  8. #8
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    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.



  9. #9
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    Nicely done!

  10. #10
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    This obviously will not fit inside the stock wheels.
    If you’re in control, you’re not going fast enough. – Parnelli Jones

    If your wife's having a good time and you're not, you're still having a better time than if you're having a good time and she's not. - Red Green

    2004 Marauder 300A - Garage Queen

    1025 of 3213. It is one of 1237 in black and one of 2000 w/o the moonroof option.

    Performance
    4:10's, rear Adco, front Eibachs w/ KYB shocks, Working oil pressure gauge, JLT CA Kit, Fumoto Oil Drain Valve, TCE SS Brake Lines, Zack big brake kit.
    Dress
    Power by Ford coil covers, Maruder sill plates, God's head steering wheel emblem, spoiler, front and rear splash gaurds, Custom dead pedal, LED lights for engine bay, interior and gauges. 64' Marauder Sail Panel for rear badge, custom God's head badge in grill.

    LOC: Clermont Florida

  11. #11
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    Quote Originally Posted by musclemerc View Post
    Nicely done!
    Thanks

    Quote Originally Posted by BigCars4Ever View Post
    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.


    Last edited by boom boom; 11-09-2020 at 07:44 PM.

  12. #12
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    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.
    -----------------------------------------------------------------------------------

    '04 Marauder #357 of 3213 - Eaton swapped - "MERCD U"
    '15 Mustang GT, performance package
    '01 BMW 740i M-Sport, manual swapped
    '18 Chevy Malibu Redline
    '03 Grand Marquis
    '08 Kawasaki ZX6R

  13. #13
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    very nicely done!!
    • 82 GT coyote swap started
    • 03 300a Marauder, stroked,cammed,T/S Trilogy Supercharged # 216,Best Et 10.77@129.72 on slicks, 93 pump gas. driven to the track.
    • 2011 GT 500, 3.4 whipple,93 pump gas,10.47@133,Driven to the track.
    • 2003 azura blue Mach 1, cobra motor,2.9 Whipple,crusher inlet,built 4r70w trans,04 IRS rear.full weight street car, Corn Fed

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