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Gauging Interest: Model S Front Caliper Upgrade Kit

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Here's some photo's of the kit mounted up. You can see my specific setup which consists of Performance Red Model S Calipers, 355mm Two-Piece Directional Rotors, StopTech Stainless Brake Lines, Raybestos ST-47 Pads, and 3" Brake Ducts.
 

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Great progress here!

Are those rotors compatible with the P3D+ calipers?

Also, you show the stock 18" wheel fitting over the Model S caliper, which is great, but they don't fit the rear P3D+ caliper.

Unless, of course, you have something in work for the rear caliper, too?
 
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Great progress here!

Are those rotors compatible with the P3D+ calipers?

Also, you show the stock 18" wheel fitting over the Model S caliper, which is great, but they don't fit the rear P3D+ caliper.

Unless, of course, you have something in work for the rear caliper, too?

Sadly, the rotors are not compatible as they are 32mm thick compared to 25mm on the P3D+ Calipers (which is one of the big benefits of this kit).

Fitting over the 18" aero wheel is most applicable to those without PUP looking to upgrade just the front brakes.

See my build thread to answer on the rear calipers, but, long-story-short, yes, there is an option but not sure it makes sense. I may mess around with it sooner than later.
 
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Awesome project build. I’d make some relief holes at the lowest point of the brake ducts just incase moisture or water gets in there from rain or washing a car and it cannot escape. Turns it into a P Trap sorta deal.
 
Unfortunately, I did not go forward with releasing this product for sale. I was not able to find a manufacturer for high volume custom two-piece rotors for this application. If you want, you can buy stock Model S/X front rotors and have them machined for the 5x114.3mm bolt pattern in the "dead" space which is what I originally did and worked fine. You will need small (~1.5mm) spacers/washers for the caliper bolts.

Alternatively, if you are mostly concerned with cosmetics just upgrade to the factory Model 3 Performance front brakes (they are reasonable affordable).

If you are concerned with performance, Mountain Pass Performance has a nice StopTech BBK and AP Racing also has a nice BBK.
 
Unfortunately, I did not go forward with releasing this product for sale. I was not able to find a manufacturer for high volume custom two-piece rotors for this application. If you want, you can buy stock Model S/X front rotors and have them machined for the 5x114.3mm bolt pattern in the "dead" space which is what I originally did and worked fine. You will need small (~1.5mm) spacers/washers for the caliper bolts.

Alternatively, if you are mostly concerned with cosmetics just upgrade to the factory Model 3 Performance front brakes (they are reasonable affordable).

If you are concerned with performance, Mountain Pass Performance has a nice StopTech BBK and AP Racing also has a nice BBK.


Would the stock non PUP rotors work with the Model S calipers?

And is there any trouble getting the rears fitted? Clarence issues on the 18" aero wheels?
 
Would the stock non PUP rotors work with the Model S calipers?

And is there any trouble getting the rears fitted? Clarence issues on the 18" aero wheels?

No, the S Calipers require a 32mm rotor which is 7mm thicker than the Model 3 rotors. Rear Performance Calipers don't really fit under the 18" Aero wheels. You can force it to work with spacers and shaving the calipers, but I would strongly recommend just getting new wheels at that point.
 
If you have Model S calipers, I recommend this kit from Racing Brake: RB BBK (355x32) Retrofit to Model S Calipers for All M3 Front
It’s a great value, and much improved performance. I installed it about a year ago and coupled with XT970 pads are great at the track. I use XT910 pads in the rear on stock, and this combination works well for me.
I got the calipers on eBay, had them powder coated and installed new pistons and seals - looks and works like new.
 

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I purchased my P3D+ with the intent of tracking it at HPDE's. It became pretty clear that the stock PUP brakes were not up to the task of track driving; at the very least new pads and brake fluid would be needed. However, pad selection was poor and the stock rotors are pretty thin at 25mm. So I began investigating ways to retrofit the Model S Calipers without it costing an arm and a leg.

I sourced Centric (StopTech) Rotors and had them custom machined and drilled to accommodate the Model S Calipers with some supporting hardware. Paired with Hawk DTC-70's and Motul RBF-600 they performed flawlessly at VIR.

I wanted to share my retrofit with the community and see if others would be interested in purchasing my kit. This kit will also work on non-performance Model 3's and those without the PUP. I am not ready to release them yet (still making some tweaks), but I also don't want to invest a bunch of time and money if no one is interested. I am guessing the kit will be in the $500-$600 range (rotors and supporting hardware, I can help source Calipers if needed, you can source pads of your choice).

Pro's:
  • Rotors are 32mm thick compared to the stock 25mm, a 28% increase in thermal capacity!
  • Fit's under the Stock 18" Wheel, PUP Caliper requires Stock 19" Wheels
  • Pads can be changed without removing the caliper, unlike the Model 3 Calipers (PUP or not)
  • Pad selection is much better
  • Cost is reasonable, you don't have to spend an arm and a leg to get a factory-feel/look BBK

Con's:
  • They are hefty at 28lbs each (compares to 21lb stock rotors), though I doubt you would notice any difference in most scenarios.
Without further ado, here are some photo's!


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Can you run the Model 3 performance 335mm rotors with the Model S front calipers?
 
What is the best M3D front brake upgrade under stock 18” wheels? The 320mm upgraded rotors don’t seem like much oh an upgrade. I would prefer using the Performance 355mm rotors because they are larger than stock and less expensive than true 2 piece rotors. Sanding/grinding M3P calipers the only option?
 
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What is the best M3D front brake upgrade under stock 18” wheels? The 320mm upgraded rotors don’t seem like much oh an upgrade. I would prefer using the Performance 355mm rotors because they are larger than stock and less expensive than true 2 piece rotors. Sanding/grinding M3P calipers the only option?
The front Performance brakes fit without any clearance issues under the stock 18" aero wheels. It's the rears that are the problem.
 
There are carbon ceramic options for Model S rotors that are significantly lighter (to your car and wallet).

And also 2-piece rotors are available with aluminum hats.
These could be a good option for 2-piece rotors:

 
It seems like there's a bunch of custom rotor manufacturers on Alibaba, Has anyone looked into the quality of Chinese made brakes?
I cannot imagine saving a few hundred dollars is worth risking your life/car. Alibaba rotors are likely not going to have any sort of QC process. Some people might have no issues, some might. There's parts you can cheap out on. The ones stopping your car isn't one of them.