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Boxster BBK OEM-ish Build

Sanderzzz

Sanderzzz

Go Kart Champion
Hello all, I know there are a few of these threads around but I figured I would create one as well as there seems to be a handful of us that are looking into this project at the same time. I'm a college student with not many places to work on projects so this project will probably be few weeks to complete. So first I figured I should list exactly what we need and where to find it all.

The brakes: Porsche Boxster 986 (non-S) Brembos
Part Number: 986-351-421-03 & 986-351-422-03
Price: I picked mine up for $125/corner on ebay



Mounting bracket: Apikol or Creation Motorsports
Price: Apikol $239 (ships from US) & CM $150 shipped (from UK)
Side note: I went with CM because I'm not in a hurry and the customs delay is worth the $100 saved.



http://creationsmotorsport.com/inde...de-porsche-calipers-brembo-vag-vw-audi-8.html

http://www.apikol.com/index.php/products/braking/a3-vw-mkv-mkvi-boxster-brake-brackets.html

Banjo Bolts and Crush Washers:
You will need these to convert your stock lines (or stainless) to the Porsche caliper
Price: $15 Shipped


https://www.ecstuning.com/b-bremmen-parts/banjo-bolt-priced-each/bq8095ss/

https://www.ecstuning.com/b-genuine-porsche-parts/copper-crush-washer-priced-each/n0138083/

Pads: Stoptech Sport (Formerly Stoptech Street Performance)
Price: $64 for the pair

http://www.rockauto.com/en/moreinfo.php?pk=2760906&cc=1417913&jsn=414&jsn=414

Paint Kit: G2 *Pick your color* (Red for me)
Price: $42

https://www.amazon.com/Temperature-Leveling-G2-Caliper-System/dp/B000AUMYMM
 
Sanderzzz

Sanderzzz

Go Kart Champion
Started out today with some basics from Home Depot to begin the cleaning process.


Supplies:
- Face masks to prevent brake dust inhalation and asbestosis.
- Latex gloves for obvious reasons.
- 3 pack of steel brushes
- 3 pack of 220 sandpaper pads
- Paint tray to mix soapy water and rinse brushes
- heavy duty degreaser/degrimer wipes
- industrial brake cleaner


^ Pics of the brakes before any cleaning ^


Round 1:
Warm water mixed with dawn dish soap applied via several oil soaked sponges. For this phase I simply tried to get the entire caliper soapy and wet while removing the worst of the oil and grime from the outer layer. Went through 3 sponges I had laying around for this and had to change out the water in the bucket several times. This is by far the messiest step but not giving enough attention here will make the following steps way more difficult than need be.



Round 2:
For this step, I swap out my soapy water for fresh warm water. The Jose Cuervo from above was to store copious amounts of hot water, I swear I'm not an alcoholic yet. I broke the caliper up into sections and went to town using a new steel wire brush. The first brush picked up too much grime in phase one and was doing more harm than good for another round of use. After aggressively brushing each section of the caliper, I rinsed using the warm water to assess what spots still had gunk stuck to them and went back to work with the steel brush.


Round Three:
For this round of cleaning, I stuck to using the degrimer wipes to take up any loose funk that the steel brush had left on the surface. I also used the wipes to get into a lot of the crevices between the pistons and in the corners. On several instances, I used the steel brush to loosen grime in troublesome spots and then picked up the remains with the wipes. The wipes were most effective on the insides of the calipers where I was hesitant to take the wire brush for fear of damaging a rubber seal.



Round Four:
Before touching the calipers, I let them air dry outside for about 20 minutes in order to assess the most problematic areas that remained. Once dry, I took my sandpaper bars to the other surfaces where I plan to paint. It's pretty incredible how the appearance changed from round three to four. The face is now entirely smooth and dust/dirt free. I made sure to attack each surface from multiple angles to ensure the most smooth and clean prepped area possible. Tomorrow I plan to attack the calipers with industrial grade brake cleaner for the first time and begin actual paint prep.



^ Here I hit the calipers with industrial grade brake cleaner as a final prep before starting the paint process. I made sure to let these air dry entirely before beginning the next step.


^^^
The first layer of paint is really by far the most discouraging part of the whole process. As you can see, streaky and thin is an understatement at best. However, the first layer of any paint job is meant as more of a base coating to give you something to work with and for future coats to fill in and grab on to. I cannot state enough how important it is to let your first layer have ample amount of time to dry. On my first caliper I did not do this and the brush left serious stroke marks when the very stiff bristles pulled paint that had not yet set onto the surface of the caliper. Not allowing enough time for the base coat to dry (30-40 minutes) will result in need an extra coat on the back end and take longer overall. TLDR: Let this layer dry, don't get discourage that actual presentation sucks at this point.

^^^
Here are the calipers after about 2 hours and 3 coats of paint. As you can see, it is a night and day difference between first and third coats. I realized along the way that it is far more advantageous to paint in shorter and heavier strokes than to thing the paint out and go with fewer dips into the can. This paint is most likely going on a use caliper and is going to need a thicker coat for that shiny smooth end product that we all want. Take you time and paint in tiny sections so that it looks even and well done. You MUST be patient and methodical with a project like this.

^^^
Here are the calipers after 3 coats of paint and 24 hours of curing time. Up close, you can see some small areas where they paint is maybe a little bit thicker than others but at the end of the day, from beyond a foot a way, these things look amazing. Behind a set of wheels, I have no doubt that they will stick out so much better than the stock calipers. I currently have a set of high temp brembo decals on the way that I will be putting on the outside of the caliper faces and covering with a layer of high temp clear gloss paint to protect the sticker from grime.
 
Last edited:
Sanderzzz

Sanderzzz

Go Kart Champion
Reserved for install
 
Sanderzzz

Sanderzzz

Go Kart Champion
Reserved for final thoughts, review, and lessons learned
 
J

Jcarollo765

Ready to race!
Damn dude, impressive!!!!

Subbed:thumbup:
 
ZiggyMKVI

ZiggyMKVI

Ready to race!
Sub'd for more brake porn
:drool:
 
PromoFLB

PromoFLB

Ready to race!
In to see the results. Great post!
 
Sanderzzz

Sanderzzz

Go Kart Champion


Brakes arrived from Cali in two days despite the snow here on the east coast. Damn I'm impressed with the USPS!



Shoutout to the local Home Depot. Got everything I needed from one aisle. Hopped over to the closest advanced auto for some extra brake cleaner to get my day started.
 
Sanderzzz

Sanderzzz

Go Kart Champion
Update on cleaning in post #2. Today was much more progress than I expected!
 
P

pcfoo

Passed Driver's Ed
Tempted to follow your steps...thanks for sharing
 
Sanderzzz

Sanderzzz

Go Kart Champion
jay745 said:
in4updates. Should have started with the brake cleaner!
Click to expand...



Yeah that might end up under the lessons learned section.
 
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