One of my main goals aside from performance (fogg mod, supersprint exhaust, bosch platinum plugs) requires that the Z be modified for high speed stability and safety (especially braking - brake fade or failure). So far I have replaced the entire suspension, shock mounts and installed a HMS sportbar.

With my first drivers school at Lime Rock Park two weeks out, it was neccessary to finally complete the brake upgrade project. After replacing the front brakes and all brake lines this weekend, my '97 1.9 is almost track ready.

Thanks to Karl Seeger for the brake upgrade idea and help as I was getting the requisite parts.

The fun this weekend invloved removing the following
1.9 brake components:

6 Rubber Brake Lines
Calipers
Pads
Rotors
Brake Fluid

And

Replace them with:

6 Goodridge Stainless Steel Brake Lines (HMS)
325 Calipers
Frozen Rotors - Vented, for a 2.8 (HMS)
EBC Red Pads - (HMS)
ATE Super Blue - (HMS)

I put this project off for a while as I wasnt too sure what to expect when removing all OEM brake lines as I feared getting air into the ABS/AST system. In retrospect I am quite amazed how easy this procedure was. From start to finish about 6 hours.

I also built this great little pressure bleeder from ACE Hardware parts, but could not realy use it as it developed a small leak in the adapter cap that attaches to the brake fluid reservoir. The modified bottle itself withstood the pressure test though. Just gota fix that cap and I know that it will work. Not too bad for $35 worth of parts.

The brake fluid catch bottle was manufactured from a empty water bottle, 1/4" OD tube and a hanger.

Since I could not use the ACE device to pressure bleed I had to resort to the tried and true one man and girlfriend/spouse/SO method to bleed the brakes - Thank You Leann!!

Damn, old OEM brake fliud is dirty and sometimes white - Super blue is real pretty by comparision - almost like estoril blue.

When flushing the fluid or bleeding the brakes, it is imperative to not let the main reservoir run empty. If it does, it will cause driveability issues - no brakes. Just replacing the front lines gave me full brake pedal travel (to the floor). I was in the garage and not moving.

There are ways to get the car driveable, but you have to bleed first and then take it out to somehow engage the ABS system to recyle it and get all air out and then you have to rebleed.

Its just a lot easier not to let the brake reservoir run dry in the first place. When I was changing the lines and during bleeding, I kept a constant eye on that fluid level and added more as needed, typically past the max line, just to be sure.

This procedure gave me additional insight on the above.

I used one liter of Super Blue.

Replacing brake components is MESSY, keep lots of shop rags around and use rubber/latex gloves. Wear old clothes Have a metal catch sheet or pan handy or turkey pan to catch fluid. I used a low profile, almost cookie sheetish pan with good results.

How does it feel?

AWESOME - the pedal feel is firm and modulating brake presure is a cinch. Really instills a lot of confidence/ re-assures the driver that the brakes are more than capable for the the job, especially for the track. For the street I do not mind that extra "Braking Reserve".

Too soon to say anything about the EBC red pads. Still gota break em in. However they are stinky when hot.

The vented cryo rotors - shiny, at least for now.

So whats left to do to make the car track compliant?

Next week I should be receiving my harness bar and 4pt belts. 2-4 weeks after that, new seats.

Since the building of this soon to be track worthy car is almost complete, my girlfriend asked me "what are you going work on when you are done with it?" I said " I dont know?" (But I figure that those "household chores/projects" I have been putting on the back burner will have to be completed sometime - oh wait, I still have to build my web site) Just then I looked up and looked her straight in the eyes and smiled - she has '98 328is.

She knew exactly what I meant with that look and said "You ARE NOT touching my car!"

What she dont know about wont hurt her - hehe

Mario