Brakes Wheels 1st Gen Tires Brake Duct Kit

Discussion in '1st Generation: 2002–06 R50, R53 & 2004–08 R52' started by mini_racer, May 27, 2009.

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  1. Metalman

    Metalman Well-Known Member
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    Pinpoint Disc Brake Cooling
    If your interested;
    Here is something we just started working on yesterday for one of our customers. We are making a custom aluminum shroud to get cool air down inside the brake disc. Part of the shroud actually forms somewhat of a seal inside the rotor hat and another disc is where the backing plate would be located. So when we are done the cool air will be fed directly to the cooling slots inside the disc.
    The project started out with a paper mockup (yellow paper structure) along with a paper template of the various bolt locations for the shrouds. The black structure in the back is the original fiberglass shroud we are replacing, as it only directs cool air towards the the brake disc. In the next couple of days we should have more the aluminum shroud finished. I'll take some more pic's.:D

    /Users/Chuck/Pictures/iPhoto Library/Modified/2009/Nov 5, 2009/IMG_0436.jpg
    /Users/Chuck/Pictures/iPhoto Library/Modified/2009/Nov 5, 2009/IMG_0431.jpg
    /Users/Chuck/Pictures/iPhoto Library/Modified/2009/Nov 5, 2009/IMG_0432.jpg
    /Users/Chuck/Pictures/iPhoto Library/Modified/2009/Nov 5, 2009/IMG_0435.jpg
     
  2. Nathan

    Nathan Founder

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    Looks like you are trying to use images right off you PC. If so in the post you can attach images. Scroll below the text entry box and you'll an entry for attachments. You can upload direct from PC or Mac from there.
     
  3. Metalman

    Metalman Well-Known Member
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  4. BlimeyCabrio

    BlimeyCabrio Oscar Goldman of MINIs
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  5. Metalman

    Metalman Well-Known Member
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    Pinpoint Brake Cooling

    We made more progress today with 1 brake cooling shroud completed.


    These two pic's are taken of the funnel that connects to the flexible air hose from the front air dam. Feeding the air into the space created by the rotor hat and on into the cooling channels in the rotor.

    http://www.motoringalliance.com/forums/attachment.php?attachmentid=143&stc=1&d=1257551809

    http://www.motoringalliance.com/forums/attachment.php?attachmentid=144&stc=1&d=1257552094

    More from a different view.

    http://www.motoringalliance.com/forums/attachment.php?attachmentid=145&stc=1&d=1257552151

    http://www.motoringalliance.com/forums/attachment.php?attachmentid=146&stc=1&d=1257552187

    http://www.motoringalliance.com/forums/attachment.php?attachmentid=147&stc=1&d=1257552249
     

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  6. roach13

    roach13 New Member

    May 14, 2009
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    [​IMG]

    Here's JCW kit installed, don't think they do much. The fastners are tearing out, it's a two part system and it comes apart.
     
  7. mini_racer

    mini_racer Well-Known Member

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    #47 mini_racer, Jul 4, 2010
    Last edited: Jul 4, 2010
    Ok, I am finally moving forward with my brake ducts as I am sick and damn tired of being plagued by heat issues. Hopefully this will be enough and I will not have to move up to a bigger brake kit. I am still running the 1st gen JCW brakes.

    My version of brake duct is essentially the Sneed kit. Utilizing a flex hose from the fog lamp location, and exiting right on the rotor. I am making a few changes from the actual kit Sneed sells though:
    1. I am not using a bracket at the bumper, I will just let the spring pressure of the hose keep it flush to the backside of the bumper cover.
    2. I will not be using the Sneed brackets at the rotor, instead I wanted to keep the rotor backing plate, or protection plate as MINI calls it and so I incorporated a short tube to hold the hose right into the OEM plate.
    Here are a few pics to show the approach and progress.
    [​IMG] [​IMG] [​IMG]

    They cleaned up and painted nicely, and are finally installed. I did have to do some adjusting on them after I had them secured to provide proper clearance of the rotor, but that was expected.
    [​IMG] [​IMG] [​IMG]

    In this last pic you can see the hose holder/bracket on the backing plate peeking out just outside the diameter of the disc in the upper left quadrant.

    So far it has been a fun project. The best welding equipment I had available at the time was Acetylene so I welded that was and it worked out fine. Quite fun for my first torch welding experience. It aint the prettiest, but it sure is strong, and after the black paint it looks plenty good enough. Obviously MIG welding would have delivered a more textbook weld appearance.

    I will post some pics of the hose routing, when I decide to tackle that part of the project, which will be soon. Also, I may eventually go with a larger fog light opening as pictured earlier in this thread, but I will start with the fog light holes.
     
  8. justintime

    justintime New Member

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    awesome job, think you could make another one? I want the same thing :biggrin5:

     
  9. mini_racer

    mini_racer Well-Known Member

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    #49 mini_racer, Jun 4, 2012
    Last edited: Jun 4, 2012
    OThanks but actually that is not an optimal design. The problem here is that we are directing cool air to the inside surface of a vented rotor. It is much more optimal to direct the cool air to the hub are such that the air can flow properly from the hub area to the perimeter of the rotor, meaning through the vents.
    ImageUploadedByTapatalk1338829768.422795.jpg ImageUploadedByTapatalk1338829819.193405.jpg ImageUploadedByTapatalk1338829862.005315.jpg ImageUploadedByTapatalk1338829890.354776.jpg ImageUploadedByTapatalk1338829941.720822.jpg


    image-1332790651.jpg



    I used a 3" hose, but 2.5" would likely work find as well. The inlet is the fog light holes in the bumper cover.

    I believe these ducts are optimal and have proved to make a difference. I used to smear XP-10 pads all over the front rotor surfaces due to heat, now I much harder and I never have any brake fade, etc.

    Simply stated...... They work!

    Edit: Disappointingly, those pics did not upload via Tapatalk at the size selected. Sorry the new pics are small.
    Ok, re-inserted a pic from Forum Runner.
     
  10. cct1

    cct1 Well-Known Member
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    I have Way's ducts, and they're good, but I have RMW's on the way--they use the fog light hole or GP ducts, and vent to the center of the hub, or about as close as you can get. These are the best I've found; just waiting for them to arrive.

    Here's a pic from Jan's car, click on it twice to supersize it:
     

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  11. justintime

    justintime New Member

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    does that little metal plate fit with 15s?
     
  12. cct1

    cct1 Well-Known Member
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    Yes--that's what I run (and what Jan runs).
     

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