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      07-14-2016, 08:45 PM   #1
kiloTHREE
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DIY: 28i to 35i Brake Upgrade

Sourced some front and rear calipers from a 335i.
Just started in on cleaning them up so it will be a bit before I have everything detailed.
Hopefully this will help others in the future.

Brakes come from a 335i 2007-2013, also found on x1 35i and Z4 E89 IIRC.



Rears go from 300mm to 336mm


Fronts go from 312mm to 348mm
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      07-15-2016, 12:22 AM   #2
vstolpner
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Ooh very interested in this! Can't wait to see more! Good luck! And wouldn't mind to how much the whole thing cost you...
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      07-15-2016, 02:06 PM   #3
spoolinX1
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Awesome. Definitely going to keep an eye on this.
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      07-15-2016, 03:26 PM   #4
kiloTHREE
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Just test fitting, front and rears bolt right up, all hardware matches. Ordered rotors today.
I'm not sure what I've seen about the rear e-brake not working correctly as everything I've read says they are the same parts but time will tell.

New caliper vs old on the front. Test fit.


Cleanup time.


Pop the pistons out using compressed air, and remove all the seals.
They all looked good and I might just replace them anyhow, no sense in doing all of this for nothing. They are going to be sandblasted and powder coated so I have to remove all the bits anyhow.

Pry the seals where the little indentations are with a screwdriver.
The inside seal comes out easily with a pick.
Obviously be careful don't tear them with a slip of the screwdriver. I'm sure you could use them again if they are in good shape but it's your time not mine. They are fairly cheap for new seals.


Everything out and clean, ready for blasting.


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      07-18-2016, 05:48 PM   #5
themishmosh
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Neat. Thanks for sharing!
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      07-22-2016, 12:09 PM   #6
kiloTHREE
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Going to be a while so don't get excited, sand blaster/powdercoat guy is backed up for three weeks.
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      07-22-2016, 01:06 PM   #7
vstolpner
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So why not just do it yourself then?!?! :-D
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      07-22-2016, 01:34 PM   #8
kiloTHREE
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Lol i wish my garage was decked out like that.
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      07-22-2016, 05:37 PM   #9
vstolpner
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Well I was thinking more basic DIY... Sandpaper, brake cleaner fluid (or something else to really clean the surface before painting), masking tape, spray paint, and a good helping of elbow grease.

That's the route I'd go with anyway, if I would even bother painting at all...
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      07-22-2016, 08:46 PM   #10
kiloTHREE
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Quote:
Originally Posted by vstolpner View Post
Well I was thinking more basic DIY... Sandpaper, brake cleaner fluid (or something else to really clean the surface before painting), masking tape, spray paint, and a good helping of elbow grease.

That's the route I'd go with anyway, if I would even bother painting at all...
Did that once before on VW R brakes, paint only holds up about 3-4 years before flaking. Do it once, do it right.
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      07-23-2016, 10:35 AM   #11
vstolpner
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Quote:
Originally Posted by kiloTHREE View Post
Did that once before on VW R brakes, paint only holds up about 3-4 years before flaking.
Good to know, I'll have to keep that in mind.
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      07-24-2016, 06:21 PM   #12
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Ohh cm'on I cant wait 3 weeks to se how this turns out, I am very interested on doing brake upgrade
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      08-17-2016, 01:32 PM   #13
kiloTHREE
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Still waiting...

Brake down of costs thus far:

salvage brakes f&r $75.00
front left rotor zim coated 34 11 6 855 000 $79.62
front right rotor zim coated 34 11 6 855 000 $79.62
right rear rotor zim coated 34 21 6 855 004 $65.96
left rear rotor zim coated 34 21 6 855 004 $65.96
pad set front Akebono 34 11 6 794 920 $86.37
pad set rear Akebono 34 21 6 790 762 $62.98
sensor front 34 35 6 792 561 $21.74
sensor rear 34 35 6 792 565 $26.24
Total thus far $563.49


I love Akebono euro ceramic pads, they are very low dust and don't have the oem bite initially (which i don't like) but give them a rotation or two they grip great.

Also choose zimmerman since they have coated rotor hats so they won't rust.

If you really want to get crazy, the Z4 "two piece" rotors with aluminum hats (34 11 6 782 593) will also fit on the front, but they do cost ~300 for a pair and only save 2lbs a corner so... yeah. Just buy lighter wheels and call it a day.

Last edited by kiloTHREE; 08-17-2016 at 01:43 PM..
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      08-26-2016, 08:03 AM   #14
kiloTHREE
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Brakes are back from coating.
A week later than expected but he ran into a lot of problems with the front calipers gassing out (natural air pockets in the casting process coming out when heated). He tried just about everything (soaking in cleaner, different powder, pre-sealing, preheating), ended up coating/stripping them 3 times before giving up.

Strangely it only happened on the front calipers, he's only ran into this only a handful of times before. Figures it's something to do with how the piece is cast.
Anyhow I didn't really care how perfect it came out, mainly just going for corrosion protection and black. Just some small bumps in the paint in a few small spots. You can see them a little on the first caliper on the second picture.

Besides when installing the rattle clips it's going to be a challenge not to scratch the piss out of it anyhow.



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      08-26-2016, 09:07 AM   #15
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They look pretty amazing! When's the big day?
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      08-26-2016, 09:23 AM   #16
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Quote:
Originally Posted by vstolpner View Post
When's the big day?
I have no idea, I'm getting married early october so time is harder to come by than I originally thought before I started this.
Should be quick since I have a power bleeder and what not but I can't risk having a car down these days.
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      08-26-2016, 12:16 PM   #17
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Congrats on the BIG big day!!! I went through that not too long ago so I know keeping the "future missis" happy is more important :-D

Best of luck!
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      09-15-2016, 06:03 PM   #18
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Great post. I have an X1 35i and although I have the upgraded gear, they have corroded. I will be doing all of this when I replace my pads.

Looking forward to seeing and hearing about the result!
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      09-19-2016, 08:46 AM   #19
kiloTHREE
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Sadly this will more than likely getting pushed back till much later this fall, far to much to accomplish for our wedding.
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      09-30-2016, 11:41 AM   #20
vstolpner
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Hope your wedding planning is going well. Just had a thought that it would be great to see the stopping distance improvement before and after the upgrade.
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      09-30-2016, 12:46 PM   #21
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Quote:
Originally Posted by vstolpner View Post
Hope your wedding planning is going well. Just had a thought that it would be great to see the stopping distance improvement before and after the upgrade.
just curious, how would one test the stopping distance? thanks.
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      09-30-2016, 01:33 PM   #22
vstolpner
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Well you could always just place a starting marker, and start breaking at that market and then measure (the most obvious way).

Otherwise you can measure using an OBD adapter. This would be either via stopping time or stopping distance, depending on the phone app you're using. Torque, for example, gives me stopping time.

For example mine shows 3.3 seconds. Assuming a straight line deceleration, that works out to be about 44m (144 feet). If adding bigger breaks then reduces it to 3.1 seconds(again, as example) then the stopping distance is reduced to 41.3m or 135 feet, or about 9 feet improvement.
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Last edited by vstolpner; 09-30-2016 at 01:44 PM..
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