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New:GT4 Essex/AP Racing Front&Rear Radi-CAL Brake Kit and PCCB-sized J Hook Discs!

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Old 12-22-2017, 09:56 AM
  #16  
JRitt@essex
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Shandingo,
Thanks so much for the kind words, and for you generosity in allowing us to borrow your car! I know it can be nerve-racking to watch your baby drive off into the sunset without you!

I wanted to also thank the rest of you for your continued interest in this exciting project. Quite a few of you have contacted us to reserve a pre-order slot for one of our new kits, and we really appreciate it! I'd also like to provide you with a couple of updates:

Forgeline Wheel Fitment- Several of you have asked whether or not our brake kit will clear Forgeline wheels without a spacer. The short answer is, yes, they will! Earlier this year Essex supplied the president of Forgeline Wheels with an almost identical AP Racing Radi-CAL brake kit for his personal Corvette, so he is very familiar with the components in our systems. He provided us with the following list of popular wheel models that will clear our kit front and rear:

Front= GE1R, GS1R, and GA1R in 19x9 +52, 19x12 +47

Rear= GE1R, GS1R, and GA1R in 20x9 +52, 20x12 +47

We'll be checking some other wheels as well, including the stock ones, but we were specifically asked about the Forgelines so I wanted to get back to everyone who asked. We'll also be posting the downloadable wheel fitment templates for those running other wheel brands.

Pre-orders- If you're interested in reserving a pre-order slot, please contact us or Apex Performance to reserve one. Our list is growing quickly, and orders will be filled in the order in which they are received. If you want a kit out of the first batch, it would be prudent to get your name on the list sooner rather than later. There's no commitment, and we don't charge our customers a dime until the final product ships out the door!

Prototype Parts- Our prototype parts are starting to trickle in, and below is a sneak peek at our caliper brackets. Our engineers pulled as much weight as possible out of them (speed holes!) while still retaining the required strength. Like all of our brackets, the production version will be anodized for added durability. Based on our current delivery forecasts from AP, we're hoping to start shipping kits by the end of February or early March.

If you don't hear more from us this month, we hope you have peaceful and restful holiday season!

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Old 02-16-2018, 11:48 AM
  #17  
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We are on the home stretch now gents! We had a GT4 in back in December, and we currently have a local GT3 back on our lift to do final fitment checks. The only difference between our kits for the two cars is that the GT3 disc hats use the center log pattern, and the GT4 kit uses the five lug.

Over the next few days I'll be posting some additional pics and info showing our components lined up with the OEM equipment. Thanks for your patience on this one...it will be well worth the wait!

Our pre-order list is getting fairly long. If you want one of our kits for your GT4 this spring, please get in touch with us and we'll add your name to our queue.

Out with the old, and in with the new.


Old 02-16-2018, 11:51 AM
  #18  
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Engineering did an outstanding job on the packaging on this one! We have miles of clearance behind the OEM GT3 wheels, and I don't expect we'll have any issues with the OEM GT4 wheels either. This bodes very well for having a wide range of aftermarket wheels fit without any type of spacer. Our friends at Forgeline have confirmed that all of their popular 19" fitments will clear our brake kit without a spacer.

Caliper to spoke on the OEM GT3 wheels at the tightest spot...plenty of space:



Wheel barrel clearance:



Rear is on the car and looking killer!



Lots more pics and info on the way, please stay tuned...
Old 02-16-2018, 11:53 AM
  #19  
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Here's the GT4 on the lift back in December when we were collecting all of the requisite data:
Old 02-16-2018, 01:02 PM
  #20  
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Below are some pics comparing the OEM calipers to the AP Racing Radi-CAL calipers we are using in our kit. We'll be posting up some comparative disc pics and other details early next week.

Our front six piston is considerably smaller, and weighs 6.1 lbs. vs. 9.3 lbs. for the OEM unit.







Our caliper isn't nearly as tall, allowing it to hug the disc more tightly, and offering fewer issues with debris in the wheel barrel/across the top of the caliper. Also note that the fluid paths in the AP Racing Radi-CAL are internal. There is no external cross-over pipe/tube from one side of the caliper to the other. Internal fluid pathways reduce the risk of the crossover tube being damaged by track debris, or by knocking a wheel against it when pulling the wheel off or putting it back on. The bleed screws on the front AP Racing calipers are also protected from those situations to a much greater extent.






The front AP Racing caliper only requires the removal of two 6mm bridge bolts for a pad change:





Our customer has about 6,000 miles total on his car, of which about 3800 are track miles, and he already has a cracked ceramic piston cap and dust boot:





Here is the rear caliper comparison. Our rear caliper is 4.85 lbs. vs. 7.5 lbs. for the OEM unit:






Pad changes on the rear AP caliper are even easier...just one bolt.
Old 02-21-2018, 10:50 AM
  #21  
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We just finished gathering the final numbers on unsprung weight savings, and it looks like our team was able to just about match the weight of the OEM PCCB brake system! The primary benefit of carbon ceramic discs vs. iron is unsprung weight savings. If you're tracking your car, that is pretty much the only tangible benefit. Our system provides the primary benefit of carbon ceramic discs, without all of the pitfalls, compromises, etc. Our system strips approximately 33 pounds of unsprung weight from the car vs. the OEM iron system, and is within 1.5 lbs. per corner of the OEM PCCB system weights. Here they are from lightest to heaviest, and all weights below are in pounds:

Front
OEM PCCB
Caliper= 9.3
Pads= 7.7
Discs= 15.2
Total brake corner weight= 32.2

Essex/AP Racing Radi-CAL BBK
CP9661 caliper= 6.1
Caliper bracket= 1.0
Pads= 5.2
Assembled discs= 21.5
Total brake corner weight= 33.8

OEM Iron
Caliper= 9.3
Pads= 7.7
Discs= 24.2
Total brake corner weight= 41.2

Rear
OEM PCCB
Caliper= 7.5
Pads= 6.1
Discs= 13.5
Total brake corner weight= 27.1

Essex/AP Racing Radi-CAL BBK
CP9449 caliper= 4.85
Caliper bracket= 0.7
Pads= 3.85
Assembled discs= 19.1
Total brake corner weight= 28.5

OEM Iron
Caliper= 7.5
Pads= 6.1
Discs= 24.0
Total brake corner weight= 37.6

Last edited by JRitt@essex; 02-21-2018 at 01:05 PM.
Old 02-21-2018, 02:41 PM
  #22  
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Is there any reasons for not using ceramic disc besides durability and high replacement cost? I've seen aftermarket offerings that use the OEM ceramic disc from the Corvette ZR1 which are much more reasonably priced than Porsche's OEM ceramic disc once it's time to replace them. I figured you might be most adept at answer this since you actually have kits that replace the ZR1's ceramic brakes with iron. Would it be possible to run a 394/380 ceramic disc with your caliper upgrade for ultimate weight savings - for curiosity's sake?
Old 02-21-2018, 03:08 PM
  #23  
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Originally Posted by jlennox
Is there any reasons for not using ceramic disc besides durability and high replacement cost? I've seen aftermarket offerings that use the OEM ceramic disc from the Corvette ZR1 which are much more reasonably priced than Porsche's OEM ceramic disc once it's time to replace them. I figured you might be most adept at answer this since you actually have kits that replace the ZR1's ceramic brakes with iron. Would it be possible to run a 394/380 ceramic disc with your caliper upgrade for ultimate weight savings - for curiosity's sake?
We don't have a caliper that would work with the ST carbon ceramic discs (which are the same dimensions as the OEM discs). There are several reasons why our calipers are not compatible. OEM-style discs tend to have a very tall radial depth, as does the pad that mates to them. Radial depth means the distance from the inner diameter of the disc to the outer diameter...essentially, the height of the swept area. For example, the iron OEM GT3 discs have a radial depth of 66mm. The PCCB's have a swept area that is 75mm. That is typical. Unlike a proper iron racing rotor, carbon ceramic discs typically do not have an efficient internal vane structure that flows a lot of air. For example, our iron front discs have 84 internal cooling vanes. Implementing such a design on a carbon ceramic disc would be both technically challenging and expensive/labor intensive. The OEM PCCB discs have about half as many, and they are not the same shape. Since they don't flow nearly as much air, Carbon ceramic discs (and their corresponding pads) are usually made to have as much surface area as possible to aid with the radiation of heat. That's why on just about every model of car that is offered with both iron and carbon ceramics, the carbon ceramics are considerably larger and have a larger radial depth. Conversely, our iron racing discs are incredibly efficient, and can be made with a smaller radial depth. In our case, the radial depth of our iron discs is 54mm. AP Racing doesn't have a caliper in its part bin that would run on a disc with a radial depth as large as the OEM setup. Doing so would mean that the caliper and pads were carrying around a whole bunch of unnecessary mass (as we see with the OEM setup). The efficiency of our setup allows us to remove a nice chunk of mass from an iron disc, while still supplying plenty of thermal capacity.
At this point, as you mentioned we've dealt with carbon ceramic discs in many markets...C6 and C7 Corvette, Camaro, Audi R8 and TTRS, Ferrari, Lamborghini, and Porsche. We have several customers who tried running carbon ceramics on their fleets of exotic cars. They found that our iron discs are the only sustainable option for their cars, which are run all day on the track. The cars were constantly down for service, and the running costs of pads, disc, and brake fluid replacements were astronomical. While the carbon ceramic technology has improved, the story remains the same across all markets...carbon ceramic discs and track use are not a match made in heaven. At some point that will almost certainly change, but we are not there yet, and we are not comfortable recommending carbon ceramic discs to our customers for track use. We don't believe that current carbon ceramic technology can match iron in the track environment. Yes, the ccm discs are lighter, but they run hotter and don't have the same durability. They most certainly don't have the same long-term running costs. Our iron competition systems have been proven over millions of miles at all levels of pro motorsports, and we believe that they offer the best blend of performance, weight, and long-term running costs. If money is literally no object and you don't mind throwing piles of it at the car, then yes, carbon ceramic discs are an option to save every last pound. Ninety nine percent of customers have at least some cost consideration however, so it's not a recommendation we make or promote.

Below are some comments from our website on carbon ceramic discs:

Carbon Ceramic is NOT Carbon/Carbon

At this stage you may be saying to yourself, "But I saw that the XYZ professional race cars were running carbon brakes at the track." The carbon brakes currently being used in professional racing are carbon/carbon (abbreviated C/C), which is actually a different material vs. the carbon ceramic discs used on road cars. The carbon ceramic brake discs on road cars are a Carbon Ceramic Matrix (CCM). In recent times many professional racing series (F1, ALMS, IRL, etc.) have switched to carbon/carbon brake discs in an effort to reduce weight. Carbon/Carbon is an outstanding lightweight material for racing, but requires heat before it starts to generate usable friction. As such, they're completely ill-suited to a typical morning commute in a road car!

Iron vs. Carbon Ceramic Brake Discs

In the past few years, Carbon Ceramic brake discs have become increasingly popular on high-end sports cars as either standard equipment or as a factory installed option. Although expensive, they're a great choice for a car that is used exclusively on the street. They save a large amount of unsprung weight, they don't generate much brake dust, have low NVH, and they may even last longer than the rest of the car! For the avid track enthusiast however, they're typically not the best choice.On the racetrack, repetitive stops from high speeds generate considerably higher brake disc temperatures vs. what could ever be legally or sanely achieved on the street. Various manufacturers producing the current crop of carbon ceramic discs claim to match iron disc durability on the track, but our experience tells us otherwise. While they may be less resistant to warping or deformation at repeated elevated temperatures, the biggest problem with carbon ceramic discs is that they tend to oxidize at track temperatures, showing rough surface eruptions on the disc face. In some cases the oxidation is terminal (chopped fiber discs), and the discs must be scrapped once it occurs. In other cases (continuous fiber discs), the discs can be resurfaced, but only a limited number of times and at a cost that would be higher than buying brand new iron discs. Most carbon ceramic discs are measured in terms of minimum mass, rather than the traditional minimum thickness used to measure iron discs. Once the minimum mass is reached, the carbon ceramic disc is typically trash. Below is an oxidized carbon ceramic disc that was driven on a racetrack ten times. Notice the dark spots in which the surface is flaking off / eroding. When your disc looks like this, it has become a $2,000 paperweight!

Other Potential Pitfalls with Carbon Ceramic Discs:
  • Low airflow- If you look at a specific car model that offers both iron and carbon ceramic discs as an option, the carbon ceramic discs will almost always be considerably larger in overall dimension, with a specific emphasis on a tall radial depth (distance from outer disc edge to inner disc edge). Whereas an iron disc uses a web of directional internal vanes to speed airflow through the disc, most carbon ceramic discs rely primarily on their large surface area to radiate heat into the air surrounding the disc. Hence, the tall radial depth.
  • Expensive and limited range of compatible brake pads- There aren't many brake pad options with carbon ceramic discs. The pads must be compatible with the specific disc material being used, and if they aren't, they can destroy the discs in a hurry. Since brake pads are a very personal choice to most track junkies, carbon ceramic discs don't provide many options for the driver to chase a desired feel. Also as noted above, carbon ceramic discs tend to be very tall radially, which means very large brake pads are required. In the world of brake pads, price is usually directly proportional to size: Bigger = more expensive.
  • Poor feel- Experienced drivers will tell you that cast iron discs provide superior pedal feel due to less compress-ability. Some drivers find that carbon ceramic discs feel soft or abrasive at lower temperatures, but feel like stone with little modulation once they heat up. Feel and the resulting confidence is rather important when hurtling towards a guardrail at 150mph!
  • High replacement disc cost- Carbon ceramic replacement discs can be hideously expensive. If you do wear out or damage a disc, it can cost thousands of dollars to replace or resurface them. When running carbon ceramic discs hard on a racetrack, the odds of having to replace one or more of them increases exponentially vs. if you only drive your car on the street.
  • Damage-prone- Many manufactures suggest covering their carbon ceramic discs when handling them, so they are not chipped or fractured. One knock when changing a wheel can destroy a disc. Additionally, some chemical wheel cleaners or abrasives used in car detailing can damage carbon ceramic discs.
  • Splinters- Carbon ceramic discs shouldn't be handled with bare hands, as they can leave carbon splinters in the skin.
  • Greater sensitivity to burnishing/bedding-in- Most manufacturers have an explicit, and sometimes intricate, set of instructions for bedding-in their carbon ceramic discs. Iron discs can typically be prepared via a simple series of stops from 60-80 mph with the brake pad of choice.

Iron Disc Benefits

So what can AP Racing J Hook iron discs do for a car previously equipped with carbon ceramic discs?
  • Increased airflow and slower heat transfer to other brake components- AP Racing J Hook discs have a unique, high-count vane design that promotes airflow, heat evacuation, and rapid cooling. They don't rely on a large surface area to cool via radiation. The iron discs will move more air than your carbon ceramic's, and as a result they won't heat your brake pads, caliper pistons, and brake fluid up as quickly. You'll be able to run longer sessions without brake fade, and you'll enjoy the confidence that comes along with them. They'll also make any brake ducts that you have on the car more effective and useful.
  • Huge range of compatible brake pad compounds- Iron discs will open up a much greater range of available brake pads. You'll be able to achieve a different feel, and tailor your brake setup depending on your needs and environment, whether that is running an AutoX or the most demanding racetrack in your area. You'll also likely be paying less per brake pad set than you were previously, and your pads will last longer.
  • Inexpensive spare discs- You'll no longer have to spend thousands of dollars when it's time to replace your discs. AP Racing J Hook's typically only cost $300-600 per iron disc ring, so you won't have to stress about anything happening to them. They're inexpensive enough that you can always keep a spare set on hand, so you won't have to worry about any brake-related downtime when you're out at the track.
  • Durability- Iron discs can take a beating. You can stash your spares in your race trailer, and you won't have to worry about handling them, covering them, dinging them, or chipping them when changing your wheels.
As you can see, although iron discs do come with a slight weight penalty, they're still the smart choice if you run your car hard on the racetrack. They're the obvious solution that has been proven countless times on tracks around the world, at all levels of motorsport.. AP Racing J Hook Discs have been proven time and again in professional racing, winning many races and championships (ALMS, Rolex, Grand Am, etc.).
Old 02-21-2018, 03:17 PM
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That was an awesome response, thank you!
Old 02-26-2018, 11:53 AM
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That was an awesome response, thank you!
No worries, glad to help!

In racing action, AP Racing Radi-CAL-equipped cars swept the Podium in NASCAR Cup yesterday at Atlanta.

Here are some comparative shots of our prototype disc/hat lined up vs. OEM. The OEM discs are a dual-cast design, which essentially means a separate hat and iron disc ring are formed as two separate pieces, and then cast together. The goal with these discs is to provide some of the benefits of a two-piece floating/racing disc, while still being able to resist the road salt/corrosion issues aluminum disc hats can have. The amount of float in these discs will be more limited than a true racing design, and as you can see in the pics, the 'arms' used to attach the hat to the disc partially obscure airflow into some of the vanes. The dual-cast design also weighs more than our fully floating 2-piece design.Cooling air enters into the back side of the disc, and brake ducts promote that airflow even further. As you can see in the pics below, the dual-cast hat design blocks considerably more airflow into the disc when compared to the AP Racing design.

Front Discs


A wide air gap and 84 directional curved vanes on the AP Racing disc vs. 60 split vanes


The back of the AP Racing disc offers a much clearer path for cooling air to enter the internal vanes. You can also see the gaps by which cooling air can flow through the hat and across the outer disc face.




As we all know by this point, drilled discs don't like heavy track use. The cracks start at the holes and continue expanding from there.




Here are the rear discs

Old 02-28-2018, 03:58 PM
  #26  
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Hello Gents,

I have a few updates for you.

Reservations and order fulfillment
All of our kit components are continuing to trickle in from AP. Based on our current status, we expect the first batch of kits to ship during the first week of April. If you have already contacted us to hold a reservation, one of our sales people will be reaching out to you within the next week or so to collect all of your order details and payment info. If you see a number with a 704 area code, that's likely us. Again, you won't be charged a dime until the day your kit actually ships out the door.

If you haven't yet reserved a kit and you'd like one this spring, I'd recommend getting your reservation in ASAP. We are getting fairly close to selling out our first wave/batch of kits, and AP is incredibly busy with pro racing season underway. It may be a little while before we see another batch of components.

More Component Details
The completed brake kit listings are now live on our website. You can see lots of details about every facet of our kit via these links:

Front Essex Designed AP Racing Radi-CAL Competition Brake Kit for 981 GT4

Rear Essex Designed AP Racing Radi-CAL Competition Brake Kit for 981 GT4

Wheel Fitment
Some additional notes on wheel fitment:
  • Our front and rear kit clear the OEM 20" wheels without spacer, and plenty of room to spare.
  • If your wheel spokes clear your OEM iron brakes, they will clear our front brake kit. The outside face of our front caliper actually sits inboard of the OEM iron setup. Again, that is wheel spokes. Our kit is going to stick out slightly further towards the wheel barrel than the OEM iron brakes, but it should still clear plenty of 19" wheels. I'll find out what exactly that number is, but we're only talking about a couple of mm.
  • Essex is not responsible for wheel fitment. If in doubt, please use our wheel fitment templates in the links below to check wheel clearance. Print the template, use a ruler to confirm that your printer didn't scale the size, tape or glue it to some cardboard, and place it in the wheel as shown in the photo below.
Front 981 GT4 wheel fitment template

Rear 981 GT4 wheel fitment template

Old 06-06-2018, 10:50 AM
  #27  
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We've been actively shipping our complete brake systems for the GT4 and GT3 for a few weeks now, and the positive feedback is starting to roll in. Due to time constraints, I've been primarily updating our GT3 thread, which you can see in the link below:

https://rennlist.com/forums/991-gt3-...t-finally.html

Feedback has been overwhelmingly positive. We've had at least three customers set personal best lap records, and one GT4 owner summarized it best after a weekend with them at Road Atlanta by saying, "These brakes are F'ing awesome!"

I wanted to share some customer images of the kit installed. Please let us know if you have any questions!











Old 06-06-2018, 11:34 AM
  #28  
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Originally Posted by orthojoe
I still don't understand why Porsche uses those stupid ceramic pucks that crack and why they bridge the caliper so we can't do quick and easy pad swaps anymore.
AP makes solid products.
Seriously, why did Porsche/Brembo bridge the caliper? Seems like a form of cost cutting and a huge step backwards.
Old 06-06-2018, 12:46 PM
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Originally Posted by ekam
Seriously, why did Porsche/Brembo bridge the caliper? Seems like a form of cost cutting and a huge step backwards.
PFC was doing a lot of jaw boning about the Brembo calipers "flexing" due to the open back. About the time PFC got on the 991 cupcar with their solid bridge calipers....the street cars did the same. Porsche has had the open back calipers since 1986. Would truly love to hear there explanation of why this was done. Would love to see them go to AP calipers on all their cars and scrap this Brembo stuff.
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Old 06-06-2018, 05:11 PM
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Originally Posted by Clark-ApexPerformance
Porsche has had the open back calipers since 1986.
911 Turbo had open 4-piston Brembos since 1978...


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