Wilwood 16" kit caliper issues

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Re: Wilwood 16" kit caliper issues

Postby bobbrown » Tue 16.09.2008, 18:19

tigerdog wrote:Even with the feedback above, since I already have all the other wilwood bits I plan to move forward with 6806s. I like the graph results of the dynapro better but can't afford to start from scratch. Since I am able to lock the fronts with my current EBC rotors and greenstuff pads, I expect I can do the same with the 6806s. Bob, if I can't, would you chock it up more to pad selection than mechanical issues?


If you already have all the parts then this is possibly the best way to go from a cost point of view, the Dynapro calipers are twice the price of the 6806's.
As far as pads go it can be tricky the as race spec pads usually do not work so well when cold.
The classic here is you are on a freeway/motorway having driven for 20+ miles with out using the brakes so they are cold, you come to use them and lo and behold the braking is not what is expected untill they warm up a bit.
There are a few alternatives for fast road use but I could not recommend a race pad for road use.
An alternative to geen stuff is a Mintex pad MDB1796-M1144 but not sure it is available over that side of the pond plus others choice as I said can be a little tricky
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Re: Wilwood 16" kit caliper issues

Postby tigerdog » Tue 16.09.2008, 20:34

Yes, all the parts including uninstalled 6816s. :| I have a set of the "Q" compound pads but no experience with them; hopefully they'll bite well enough cold. I don't track the car but "spirited" road driving does happen occasionally. I'll have to favor a pad with good bite when cold over extended performance when hot. On a previous cars, I've used Axxis Metalmasters with reasonable results - still not great cold but heat quickly and bite like mad when warm. I haven't seen them mentioned here in the forum so maybe they're not available in the UK.
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Re: Wilwood 16" kit caliper issues

Postby nitroman » Wed 17.09.2008, 05:34

Code: Select all
Caliper  F&R piston   Incr/Decr     sq-mm     Braking %   Bias Incl.  Incr/Decr
 Type     area sq-mm    VS Stock   Front/Rear  Front/Rear  Disc Size    Newtons
=======  ==========   =========   ==========  ==========  =========   =========
OE          6172         --       4248/1924     69/31       70/30        --
#6806       5795        - 6%      3871/1924     67/33       73/27       +13%
#6811       7231        +17%      5307/1924     73/27       78/22       +55%
#6816       8146        +32%      6222/1924     76/24       81/19       +82%

Above I've added a column which takes the larger size of the front rotor into account. Note that even the OE Elan has a larger front rotor than rear, although not to the degree the Wilwood kit uses.
Added one more column which is the true "amount of energy available to pull Elan to a stop" (as long as you don't lock the wheels). The last 2 columns are real-world representations taking both rotor OD & clamping-force into consideration. The 1st five columns only address total piston-area, making column 3 represent the relative distance your brake-pedal will move.

Everything considered, I have 2 unused 16" kits missing only the 4-pot calipers. I think I'll try the 120-6811 caliper for the kit I'm installing on my yellow car, making further decisions based on the result. Here's why: My white M100 has the mojo stoppers on it. Driving one M100 followed by another with less powerful brakes is a risk to my well-being. The 6811 calipers should still provide noticably increased braking, while almost halving the increased pedal travel.

I like stopping faster. I finish my braking a nanosecond being turning into corners, so braking IN a corner is an extreme rarity. Today I had to slide over in front of a semi, speeding up to get in the proper lane before my exit, then braking abruptly. I could not have done so with any less "stop".

The higher your deceleration level, the more weight transfer takes place, reducing the weight on the rear tires and increasing it on the front. If anything, you’d now want to decrease the rear effectiveness, which the "mondo" Wilwood brakes do. Vehicle stability under braking requires that the rear brakes do NOT lock before the front brakes. When an OEM is designing a brake system, they 'size' the system components (calipers, rotor OD) to generate the proper amount of torque at both ends of the vehicle so that the front brake force exceeds its peak traction first. At this point, the front brakes lock and the car slides in a nice, stable straight line.

The Potential Impact of “too big” Front Brakes:
Considering front bias, can you have too much bias? Certainly. Too much front brake will leave the front doing more work than necessary and possibly lead to over heating. But too much rear can create an unstable and "tail happy" feeling making braking quite dangerous. A well-designed brake system should always lock the front first. If the rear wheels lock, the car will spin around. In fact, the purpose of rear proportioning valves is to ensure that line pressure cannot rise to the point of rear lock up.
Fortunately (from a safety standpoint anyway), big-front-brake suppliers adapt a mondo rotor and caliper package to a vehicle. They end up actually increasing the FRONT bias. However, they are not pushing the vehicle toward instability. If they were, every one of them would have been sued out of existence.
Last edited by nitroman on Thu 05.03.2009, 04:18, edited 8 times in total.
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Re: Wilwood 16" kit caliper issues

Postby tigerdog » Wed 17.09.2008, 07:40

6811? Oh no, yet another choice! Nitroman, please let us know how these feel compared to the 6816s.
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Re: Wilwood 16" kit caliper issues

Postby bobbrown » Wed 17.09.2008, 09:38

nitroman wrote:
The higher your deceleration level, the more weight transfer takes place, reducing the weight on the rear tires and increasing it on the front If anything, you’d now want to decrease the rear effectiveness, which the "mondo" Wilwood brakes do. Vehicle stability under braking requires that the rear brakes do NOT lock before the front brakes. When an OEM is designing a brake system, they 'size' the system components (calipers, rotor OD) to generate the proper amount of torque at both ends of the vehicle so that the front brake force exceeds its peak traction first. At this point, the front brakes lock and the car slides in a nice, stable straight line.

The Potential Impact of “too big” Front Brakes:
Considering front bias, can you have too much bias? Certainly. Too much front brake will leave the front doing more work than necessary and possibly lead to over heating. But too much rear can create an unstable and "tail happy" feeling making braking quite dangerous. A well-designed brake system should always lock the front first. If the rear wheels lock, the car will spin around. In fact, the purpose of rear proportioning valves is to ensure that line pressure cannot rise to the point of rear lock up.
Fortunately (from a safety standpoint anyway), big-front-brake suppliers adapt a mondo rotor and caliper package to a vehicle. They end up actually increasing the FRONT bias. However, they are not pushing the vehicle toward instability. If they were, every one of them would have been sued out of existence.


I do not totally agree with what you are saying here and it is a little miss leading.

Lets take a look at weight transfer, the amount of weight transfer is limited by tyre grip so as you can lock the fronts with the standard brake setup saying you get more weight transfer with big brakes is a myth, a simple physical impossibility.
Ok I agree that locking the rears first is not a good thing, but then neither is having too much front bias, in fact with too much front bias you can increase yes increase the overall stopping distance.
I agree that the manufacturer does endeavour to get the balance of the brakes correct but you have to take into account changing road surfaces, conditions and different tyres, all of which effect the maximum load that can be placed on the wheels before they lose grip. They do extensive testing on a variety of surfaces over a long period of time to check they have it correct, and adjust the setup accordingly.

I agree you can have too much front bias but where did this heat bit come from?
The standard brakes do not cope very well with aggressive driving, never mind track use, this we all I feel know, by increasing the size of the fronts you should get better heat dissipation as this is what brakes do. They take the kinetic energy and simply convert it to heat and then dissipate the heat in to the surrounding air.
If you increase the fronts beyond a certain point then the amount of braking force that can be applied to the car will be overall reduced
Losing traction on the front tires is not as bad as the rear. You usually just plow forward until the driver lightens up enough on the pedal to regain control. Whatever the percentage is for your particular car, the front tires should lock up slightly before the rear tires under hard braking.
Most manufacturers tune the brakes setup to be front bias, they like our cars to be front-biased in all conditions achievable by the tires offered on the vehicle. This helps to insure vehicle stability under braking by the mass public. If we measure stopping distance of the vehicle as delivered from the showroom floor, we have a good benchmark for a vehicle with a 5% to 10% front brake bias. That 5 to 10% is not the brake split e.g. 70/30 but a % bias to the front such that on a car with 70/30 split the ideal is around 65/35.
You can be certain of one fact if you increase the front bias your braking distance will go up yes I said up.

If you put a car with standard brakes (in good condition) up against a car with too much front bias the standard car will stop in a shorted distance, FACT.
And lets not forget that changing the pads alone can change the bias of the brakes e.g going from say a 35u to a 45u pad can change the bias from say 71/29 split to 76/24.
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Re: Wilwood 16" kit caliper issues

Postby bobbrown » Wed 17.09.2008, 09:54

tigerdog wrote:6811? Oh no, yet another choice! Nitroman, please let us know how these feel compared to the 6816s.


It is NOT as simple as "feel" its to do with stopping distances the 6811's are too big.
I will put my neck out here and will state categorically that increasing the front bias by these amounts (both 6811 and 6816's) will lead to greater stopping distances. The perception and it is only a perception that the brakes are better is a myth, try it for yourselves see how far you need to travel to bring the car to a stop from a given speed never mind what they feel like, it is the results that matter.
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Re: Wilwood 16" kit caliper issues

Postby bobbrown » Wed 17.09.2008, 10:05

BTW

The rear piston size is 35mm
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Re: Wilwood 16" kit caliper issues

Postby RayD » Wed 17.09.2008, 10:48

If when Lotus did the brake testing and choosing the various parts they got it exactly right... then presumably any upgrade would need to go up in proportion to the original. The rear brakes would need upgrading to the same degree as the fronts.

While ‘time’ might not figure in the calculations I think it might do in people perception of how good the brakes are. If it takes more effort to 'lock the wheels' on a standard set up it probably takes more time.

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Re: Wilwood 16" kit caliper issues

Postby bobbrown » Wed 17.09.2008, 11:10

RayD wrote:If when Lotus did the brake testing and choosing the various parts they got it exactly right... then presumably any upgrade would need to go up in proportion to the original. The rear brakes would need upgrading to the same degree as the fronts.

While ‘time’ might not figure in the calculations I think it might do in people perception of how good the brakes are. If it takes more effort to 'lock the wheels' on a standard set up it probably takes more time.

Ray

If you look at the Wilwood upgrades they closley mirror the original setup and only increase the braking forces on the front by small amounts. The 6816 caliper on the other hand does increases the front braking by some considerable amount to a point where the braking distances will go up by some margin.

People often miss the reason for upgrading their front brakes and that is HEAT or rather the dissipation of it, that is what you need to get rid of when you brake.
Rears do not suffer with the quite the same issues of heat as the front as the braking loads are that much lower hence the fitting of non ventilated rears being more common.
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Re: Wilwood 16" kit caliper issues

Postby RayD » Wed 17.09.2008, 12:20

I understand what you’re saying Bob, and particularly about the 6816’s. Like you, I don’t subscribe to bigger is better.

I was trying to get the point over that if someone chose to fit 6811’s on the front they would need to upgrade the rears by the same amount in order to be in keeping with the Lotus ‘recommendation’

While the rears don’t suffer the same issues of heat, they need to keep up with the fronts... I mean...lag behind to the same degree.

Presumably the original pad material was same back and front??

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Re: Wilwood 16" kit caliper issues

Postby tigerdog » Wed 17.09.2008, 14:24

tigerdog wrote:6811? Oh no, yet another choice! Nitroman, please let us know how these feel compared to the 6816s.

Never mind... 6806 it is. :)
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Re: Wilwood 16" kit caliper issues

Postby RayD » Wed 17.09.2008, 15:07

Here you can see the difference in temperature, having said that I wouldn’t want to put my bare ar$e on the back ones... :shock:
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Re: Wilwood 16" kit caliper issues

Postby nitroman » Wed 17.09.2008, 20:24

bobbrown wrote:…the amount of weight transfer is limited by tyre grip so as you can lock the fronts with the standard brake setup saying you get more weight transfer with big brakes is a myth, a simple physical impossibility.
If you can lock the OE front brakes in a progressive, controllable manner then what you are saying is true. Many of us have found that impossible, however.

bobbrown wrote:The 6816 caliper on the other hand does increases the front braking by some considerable amount to a point where the braking distances will go up by some margin. [] If you increase the fronts beyond a certain point then the amount of braking force that can be applied to the car will be overall reduced.
If it caused us to lock the front wheels you would be correct. Don’t forget though, that larger caliper pistons multiply a person’s (his foot & leg) mechanical advantage, which allows him to modulate/control the pedal with more physical precision (he now controls exactly how much pressure he applies to the brake pedal). That is the physiology of how the human body works... "the same hand that can pick up a feather can also punch someone in the face!" The feather is an application of controlled precision, whilst the other is maximum effort somewhat out of control. In the same manner, when a certain effort level is exceeded, I am merely "punching" the OE brakes, not controlling them.

In the end, given an identical car, 2 drivers will set that car up differently in deference to their driving technique. For me (and maybe only for me), I can stop much faster, and in much less distance with more powerful brakes. That is not some ivory tower "this plane is designed to break the sound barrier" claim. That is my real-world reality.
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Re: Wilwood 16" kit caliper issues

Postby RayD » Wed 17.09.2008, 21:41

RayD wrote: While ‘time’ might not figure in the calculations I think it might do in people perception of how good the brakes are. If it takes more effort to 'lock the wheels' on a standard set up it probably takes more time.


nitroman wrote:
bobbrown wrote:…the amount of weight transfer is limited by tyre grip so as you can lock the fronts with the standard brake setup saying you get more weight transfer with big brakes is a myth, a simple physical impossibility.
If you can lock the OE front brakes in a progressive, controllable manner then what you are saying is true. Many of us have found that impossible, however.


I understand you can’t get any more weight transfer...but can you get the same amount more quickly using bigger front brakes?

If you shot a 2” steel shaft simultaneously through both front wheel spokes at speed, the weight transfer would take place quicker than it would using a more conventional form of braking...surely.

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Re: Wilwood 16" kit caliper issues

Postby paulrwebster » Wed 17.09.2008, 22:10

bobbrown wrote:
tigerdog wrote:I will put my neck out here and will state categorically that increasing the front bias by these amounts (both 6811 and 6816's) will lead to greater stopping distances. The perception and it is only a perception that the brakes are better is a myth, try it for yourselves see how far you need to travel to bring the car to a stop from a given speed never mind what they feel like, it is the results that matter.


Let's prove it then. I will go out tomorrow and measure the stopping distance at 30mph with 16" Wilwood Upgrade and 120-6806 calipers. If someone else can do the same with 120-6816 calipers, stock brakes, AP's, Brembos, 15" Wilwoods and whatever else, we can build a picture of how we stand. I have driven Chris T's car with the AP upgrade (with racing pads), Wilwood 16" 120-6816, Wilwood 16" 120-6806 and stock. I think that we will find that AP are best follwed by 120-6816, then 120-6806 and finally stock. The stock always gave me a "there is something wrong with these brakes, I'm not going to stop" feeling. The 120-6816 were great until the road was drenched when I had the "OMG I cant touch the brakes without locking one of the wheels and twitching feeing". The 120-6806 setup leaves me feeling "These just feel like normal brakes, I paid £600 just for this" and the AP with racing pads is the "jeez that stopped quickly setup".
Good luck to it!
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Re: Wilwood 16" kit caliper issues

Postby bobbrown » Wed 17.09.2008, 23:28

paulrwebster

That is an interesting experiment and I am sure you will find the results interesting, and rather suprising.
It may get a little tricky to do in practice as there are other factors to take into account , road surface, tyres and any speedo errors (could be 10%).

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Re: Wilwood 16" kit caliper issues

Postby paulrwebster » Thu 18.09.2008, 17:28

Using 120-6806 calipers with the Wilwood 16" upgrade I can stop from 30mph in 22 feet 7 inches. I had three goes at it, two were precisely the same and the third go was about a foot longer.
This looks good against the highway code figure of 45 feet (14 metres) plus thinking time, however I then tried it in my Vauxhall Zafira and came in 5 feet less with slight wheel locking.
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Re: Wilwood 16" kit caliper issues

Postby paulrwebster » Thu 18.09.2008, 18:31

Just found some brake testing figures on the stock brakes in Autocar & Motor 4 July 1990. Distance from 30mph in neutral with 50lb of load (the highest that they tested) is 26 feet. So the setup I have is better than stock brakes when new

Stock brakes when new: 26 ft
Wilwood 16" 120-6806 22 ft 7 in
Vauxhall Zafira 18 ft
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Re: Wilwood 16" kit caliper issues

Postby Paul.P » Thu 18.09.2008, 19:31

paulrwebster wrote:Stock brakes when new: 26 ft
Wilwood 16" 120-6806 22 ft 7 in
Vauxhall Zafira 18 ft


Although these figures are very interesting, what we need is the braking distance with the 6816 calipers, although we will never have accurate distances with different people doing them, as different tyres, different road conditions, different brake pads etc.
I have been following this thread with interest, & knowing that Monty tracks his car hard with the 6816 calipers, & has never spun it due to the brakes, & having had to perform a couple of emergency stops in the last 18mnths without the back trying to overtake the front, i am quite happy to stick with the 6816's unless its proven that they are either dangerous or worse than standard, neither of which had been reported in 2 yrs of use, until this thread was started :|
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Re: Wilwood 16" kit caliper issues

Postby Doug » Thu 18.09.2008, 22:06

Paul.P wrote:I have been following this thread with interest, & knowing that Monty tracks his car hard with the 6816 calipers, & has never spun it due to the brakes, & having had to perform a couple of emergency stops in the last 18mnths without the back trying to overtake the front, i am quite happy to stick with the 6816's unless its proven that they are either dangerous or worse than standard, neither of which had been reported in 2 yrs of use, until this thread was started :|


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