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  1. #1
    Veteran Member Four Rings gotaudi's Avatar
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    2001 A4 1.8T
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    Re: Actual Brake Improvement

    Quote Originally Posted by ModifiedA4 View Post
    as long as the pads and tires can handle it, and all other things being equal, larger rotors will always decrease braking distance.
    But by how much???
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  2. #2
    Veteran Member Three Rings
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    Re: Actual Brake Improvement

    Quote Originally Posted by gotaudi View Post
    But by how much???
    by the ratio of the diameters of the rotors.

  3. #3
    Veteran Member Four Rings gotaudi's Avatar
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    Re: Actual Brake Improvement

    Quote Originally Posted by ModifiedA4 View Post
    by the ratio of the diameters of the rotors.

    really? So if you increase to diameter of the rotor by 33% you decrease the breaking distance by 33% ???
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  4. #4
    Veteran Member Three Rings
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    Re: Actual Brake Improvement

    Quote Originally Posted by gotaudi View Post
    really? So if you increase to diameter of the rotor by 33% you decrease the breaking distance by 33% ???
    sure, all else being equal.

  5. #5
    Veteran Member Four Rings onemoremile's Avatar
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    99.5 A4 Avant, 01 allroad
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    nw michigan.

    Re: Actual Brake Improvement

    Quote Originally Posted by gotaudi View Post
    really? So if you increase to diameter of the rotor by 33% you decrease the breaking distance by 33% ???

    Absolutely not. Increasing rotor size does nothing to increase the tire's ability to slow the car. That ability is limited by traction and nothing more. Picture a powerlifter with an injured back or shoulder. No matter how great the force he can only apply a portion.

    Increasing rotor size does do a few nice things including adding more mass to act as a heat sink, more interior and exterior cooling area, more leverage (brake torque), larger and/or longer area swept by the pads, etc. This is offset by the larger diameter which means you have a larger flywheel to accelerate and decelerate. This drawback is rarely a big deal and is often offset by weight reduction through the use of an aluminum hat.

    This is a subject that quickly gets buried in data and that is why it is hard to understand. We've got to deal with static and dynamic weight distribution. If a car has bad brake dive then it puts more weight on the fronts which let them do more work and takes weight away from the rears so they can do less. If you limit brake dive this weight transfer is limited and the rears can do more work. How much of a difference is some labor intensive math best left to computer modeling.

    For example, this is my car threshold braking at Gingerman Raceway. It is shown on stock sport suspension with A8 brakes, Carbotech Bobcat pads, and 235/45-17 Pilot Sports. The brake dive is quite bad and the rears didn't lock up or trigger the ABS. That was mostly because I let off at about 30-40 mph for the corner. With the coilovers (balanced KW V1) and everything else the same my brake distance dropped quite a bit. I didn't measure it but there are three brake markers and I was about even with the first rather than hitting the brakes while still approaching it. Keeping the car flatter lowered the stopping distance.

    Now it gets a little trickier. I switched to more aggressive track pads (Carbotech Panther) and Toyo RA1 track tires but left everything else alone. I even ran the same rotors. The stopping distances were insanely short. An instructor rods with me to help me tighten up some lines and every time we passed the first and second brake markers he was stomping the floor and bracing for impact like a panicked driver's ed instructor. We never once dropped a wheel off the track. Again I didn't measure but I'd guess the distances were 50-100 feet shorter and we were coming in hotter since the tires let me carry more speed out of the previous corner. Where the math gets tricky is that the track tires have more grip which leads to more weight transfer so the rears were doing less work than with the street tires. If I switched to track pads in the rear they might have locked up or not been able to get up to operating temp and been even worse. The only way to really find out is to experiment or do the long math which still only gets you in the ballpark.



    One thing I've always pondered is the way a lot of VWs sit lower in the rear. In theory that jacks weight to the rear and under threshold braking the rears would carry a little more weight and be able to do a little more work. I've got no idea how this would work in real life and it may compromise cornering which could lead to even slower lap times.

    Anyone is welcome to ride along for a demonstration. I can be at the track most summer weeknights for test and tune and we might be able to borrow a Porsche for comparison. All I ask is that you have a helmet, no polyester, and an empty stomach.
    Jim

    We cannot achieve the future by being timid. It requires aggressive imagination.

    I Do Werk.

  6. #6
    Registered Member One Ring
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    Re: Actual Brake Improvement

    Quote Originally Posted by onemoremile View Post
    If you limit brake dive this weight transfer is limited and the rears can do more work. How much of a difference is some labor intensive math best left to computer modeling.
    You cannot transfer weight on your vehicle by braking, turning or accelerating. As long as you don't count your ego on the passenger seat sliding around.

    Load, on the other hand, can most certainly be transfered.

  7. #7
    Veteran Member Three Rings audinutt's Avatar
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    Jan 11 2007
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    2001 A8l 2001 A4TQM Avant
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    texas

    Re: Actual Brake Improvement

    So Joey, are you saying i was correct that on the a4 you CAN upgrade the front brakes and it WILL decrease stopping distances.

    Thanks,
    -Richard
    2001 Audi S8
    2011 Q7 TDI
    2001 A4 TQ Avant

  8. #8
    Registered Member One Ring
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    Re: Actual Brake Improvement

    Quote Originally Posted by audinutt View Post
    So Joey, are you saying i was correct that on the a4 you CAN upgrade the front brakes and it WILL decrease stopping distances.

    Thanks,
    -Richard

    Yes. Any arguments against this being the case presented here had large, factual, real world errors. Which is great, considering the person who posted them made fun of engineers who he claimed did the same thing.

  9. #9
    Veteran Member Four Rings djwimbo's Avatar
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    Feb 15 2008
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    E46 323i 5-Sp
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    Re: Actual Brake Improvement

    Quote Originally Posted by Joey T View Post
    You cannot transfer weight on your vehicle by braking, turning or accelerating. As long as you don't count your ego on the passenger seat sliding around.
    You're talking about one of the most intelligent guys I know.
    And YES, weight transfers. Whether you call it "load" or not, your suspension, tires, etc. all "see" it as weight.

    As far as making fun of other engineers, they've all made grave mistakes. You know who ends up fixing the problems engineers make? People in the field, that have real world experience. Not everything works like it does in a lab.
    Don't get me started on how TECHNICIANS have to fix what ENGINEERS have fuct up over the years.

    As far as the original question, topic, whatever...
    If you want a usable brake upgrade, go with the A8/TT rotors up front, a quality set of stainless steel lines and a high end brake fluid. At this point tires will be the limiting factor.
    Upgrading the brakes correctly will improve stopping distances.

    Personally I have A8 front rotors (slotted) and Slotted rears, both with matching brake pads. Always make sure the front and rear friction material is the same. This is one of the reasons you want to do both sets of brakes at the same time.
    My first A4 had a stickier brake pad in the rear, and on a panic stop(or AutoX stop box), the rears would lock up and walk the ass over about a foot.
    I am very happy with my braking performance. Side by side comparison between my car and my roommate's built Turbo Miata(1000lb advantage) was damn close. His advantage was in the tires he was using. 60-0 was within a car length w/ me on all seasons.
    "Thank god I had my body, because it felt so good."

  10. #10
    Veteran Member Three Rings
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    Jun 19 2007
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    2012 JSW TDI
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    Raleigh, NC

    Re: Actual Brake Improvement

    Quote Originally Posted by djwimbo View Post
    And YES, weight transfers. Whether you call it "load" or not, your suspension, tires, etc. all "see" it as weight.
    *technically* weight is the force resulting from gravity's effect on a mass...

    so unless gravity or mass change weight doesnt change...

    semantics, i know..

  11. #11
    Veteran Member Four Rings onemoremile's Avatar
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    99.5 A4 Avant, 01 allroad
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    nw michigan.

    Re: Actual Brake Improvement

    Quote Originally Posted by Joey T View Post
    You cannot transfer weight on your vehicle by braking, turning or accelerating. As long as you don't count your ego on the passenger seat sliding around.

    Load, on the other hand, can most certainly be transfered.
    It may not seem like it after reading through this thread but I really don't have any ego. I'm a student of everything and love nothing more than gaining a deeper understanding of any given subject. In this case I've chosen what I believe to be an excellent teacher. A few friends that do what he does have also shed some light on the subject. These guys aren't professors of physics they are engineers and scientists running countless real world tests and virtual simulations. A prof can tell you what he would do but these guys show you what they've done. Would you rather read a book on track driving or ride shotgun with Randy Pobst? We're talking about the real world here as viewed from behind a helmet visor not from a lecture hall.

    Load is the correct term but it is often referred to as weight, weight transfer, weight jacking, etc.. The terminology is definitely different in the paddock. I've never heard a driver or chief use the term load transfer. Lots of things are misnamed like the proportioning valve. Such is life.

    -----------------------
    You guys aren't arguing with me but James Walker Jr.. Take a little look at his bio. Maybe he doesn't have the experience or knowledge that you guys possess but I know he's a hell of a lot smarter than I am. Although qualifications are not always indicative of talent, I'm going to go out on a limb here and say that he probably knows a little something or two.

    James Walker, Jr.
    StopTech Consultant


    James Walker, Jr. is currently the supervisor of vehicle performance development for brake control systems at Delphi Energy & Chassis. His prior professional experience includes brake control system development, design, release, and application engineering at Kelsey-Hayes, Saturn Corporation, General Motors, Bosch, and the Ford Motor Company. Mr. Walker created scR motorsports consulting in 1997, and subsequently competed in seven years of SCCA Club Racing in the Showroom Stock and Improved Touring categories.

    Through scR motorsports, he has served actively as an industry advisor to Kettering University in the fields of brake system design and brake control systems. In addition, Mr. Walker contributes regularly to several automotive publications focusing on brake system analysis, design, and modification for racing and other high-performance applications. He is a recipient of the SAE Forest R. McFarland Award for distinction in professional development/education. Mr. Walker has a B.S. in mechanical engineering from GMI Engineering & Management Institute.

    To find out more about Mr. Walker and scR Motorsports, visit their website at www.teamscR.com.
    -----------------------


    The ever-present weight transfer phenomenon

    Let’s assume we have a 2500 pound car with a 50/50 static weight distribution. If we are only concerned with the vehicle at rest, it’s easy to determine the weight on each wheel. We just need to find some scales and weigh it. The sum of the front corner weights is equal to the front axle weight (1250 pounds), and the sum of the rear corner weights is equal to the rear axle weight (also 1250 pounds). The weight of the vehicle is of course equal to the sum of the two axle weights (our original 2500 pounds), and this weight can be thought of as acting through the vehicle’s center of gravity, or CG. Figure 1 sums it up nicely.


    Note that when at rest, there are no horizontal (left or right) forces acting on the vehicle. All of the forces are acting in a vertical (up and down) direction. But what happens to the vehicle when we start to apply forces at the tire contact patch to try to stop it? Let’s find out.

    During braking, weight is transferred from the rear axle to the front axle. As in cornering where weight is transferred from the inside tires to the outside tires, we can feel this effect on our bodies as we are thrown against the seat belts. Consequently, we now need to add several more arrows to our illustration, but the most important factor is that our CG now has an deceleration acting on it.

    Because the deceleration force acts at the CG of the vehicle, and because the CG of the vehicle is located somewhere above the ground, weight will transfer from the rear axle to the front axle in direct proportion to the rate of deceleration. In so many words, this is the effect of weight transfer under braking in living color.

    This deceleration force is a function of a mechanical engineer’s most revered equation, F=ma, where F represents the forces acting at the contact patches, m represents the mass of the vehicle, and a represents the acceleration (or in our case, deceleration) of the vehicle. But enough of the engineering mumbo-jumbo – just have a look at these additional factors in Figure 2.


    n Figure 3 (the beginning of what we call a “fishbone diagram” – more on this later), we see how our 2500 pound vehicle with 50/50 weight distribution at rest transfers weight based upon deceleration. Under 1.0g of deceleration (and using some typical values for our vehicle geometry) we have removed 600 pounds from the rear axle and added it to the front axle. That means we have transferred almost 50% of the vehicle’s initial rear axle weight to the front axle!

    FIGURE 3.



    At this point, the brake system we so carefully designed to stop the vehicle with a 50/50 weight distribution is going to apply too much force to the rear brakes, causing them to lock before we’re getting as much work as we could out of the front brakes. Consequently, our hero is going to get that white-knuckled ride we talked about earlier because he creates more tire slip in the rear than the front, and it’s going to take longer for him to stop because the front tires are not applying as much force as they could be.
    So what influences brake bias?

    If we look at the equations we have developed, we see that all of the following factors will affect the weight on an axle for any given moment in time:

    · Weight distribution of the vehicle at rest
    · CG height – the higher it is, the more weight gets transferred during a stop
    · Wheelbase – the shorter it is, the more weight gets transferred during a stop

    We also know from fundamental brake design that the following factors will affect how much brake torque is developed at each corner of the vehicle, and how much of that torque is transferred to the tire contact patch and reacted against the ground:

    · Rotor effective diameter
    · Caliper piston diameter
    · Lining friction coefficients
    · Tire traction coefficient properties

    It is the combination of these two functions – braking force at the tire versus weight on that tire – that determine our braking bias. Changing the CG height, wheelbase, or deceleration level will dictate a different force distribution, or bias, requirement for our brake system. Conversely, changing the effectiveness of the front brake components without changing the rear brake effectiveness can also cause our brake bias to change. The following table summarizes how common modifications will swing bias all over the map.








    Last edited by onemoremile; 06-19-2008 at 08:56 AM.
    Jim

    We cannot achieve the future by being timid. It requires aggressive imagination.

    I Do Werk.

  12. #12
    Senior Member Three Rings
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    Jan 21 2008
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    Re: Actual Brake Improvement

    Perhaps some of the mixed results for the Porsche BBK is from mounting the calipers backwards, ie, larger piston leading instead of trailing?

  13. #13
    Senior Member Two Rings
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    Athens Greece

    Re: Actual Brake Improvement

    Quote Originally Posted by mysman View Post
    Perhaps some of the mixed results for the Porsche BBK is from mounting the calipers backwards, ie, larger piston leading instead of trailing?
    u have to mount them corectly=smaller piston leading.Therefore u unscrew the bleeder valves and the conecting pipe and switch them over.Voila!

  14. #14
    Senior Member Three Rings
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    Jan 21 2008
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    Re: Actual Brake Improvement

    Yeah, I knew that, lol. But if you don't, and piece together a kit, you get it backwards. Besides tapered pad wear, it would probably be harder to modulate the pedal during rapid stops.

    Quote Originally Posted by rogerius View Post
    u have to mount them corectly=smaller piston leading.Therefore u unscrew the bleeder valves and the conecting pipe and switch them over.Voila!

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