SW Spec Chevrolet Camaro ZL1 1LE Retrofit Big Brake Kit Tech Guide

BC-61 and BC-42 calipers are Genuine GM calipers from Chevrolet MKVI ZL1, ZL1 1LE, and 2009-2015 Cadillac CTS-V.

(Detailed variant Info:https://racingbrake.com/cadillac-4/, https://racingbrake.com/camaro-11/).  

The rear BC-42 calipers can also be found on Tesla Model S or Maserati Ghibli Q4 (https://racingbrake.com/tesla-2/; https://racingbrake.com/maserati-2/)

Caliper Model/Parts Number   Caliper Model Front BC-61 (30/34/38x32) Rear BC-42 (28/32x30) Front Parts Number 20982719 & 20982734 89047743 & 89047742 Rear Parts Number 84229191 & 84229190 1042642-00-A & 1027643-00-A (Tesla Motor) 20B6770001 1A & 20B6770001 1B (Maserati)

 

Building Process:

Step one: Sourcing original calipers

Front calipers are sourced new directly from ACDelco with original boxes included (https://www.acdelco.com/). Rear calipers are sourced from GM, Tesla Motor, or Maserati, these calipers are massively produced by Brembo®.

Step two: Machine the calipers

ZL1 Retrofit Big Brake Kit requires complicated modifications on both front and rear calipers. The hardest part of the ZL1 Retrofit Big Brake Kit is machining the mounting lugs. We use a 3-axis CNC machine to trim down the factory mounting lugs and make the radial mounting holes after. We maintain a similar distance as the original radial mount Brembo® calipers to guarantee safety.

 

CNC Video:

https://www.youtube.com/shorts/7TJeGFVKZDQ

Step Three: Sand Blasting

Proper sandblasting is required for the calipers before having them repainted even when the front calipers are brand new. We professionally rebuild and check the threads on the rear calipers to ensure they are ready for the next step.

Last Step: Painting

After the proper repaint, We will have our calipers ready.

Weight:

Caliper:

The machined ZL1 front caliper is approximately 7.5 lbs, the rear caliper is approximately 4.5 lbs

The Brembo® GT-6 front caliper is approximately 7.5 lbs.

(https://blog.racetechnologies.com/2015/04/16/how-much-does-a-brembo-performance-big-brake-system-weigh-vs-o-e-components/)

Rotor:

Signature Werks Heat-Treated High-Carbon rotor weighs 18.5 lbs (355mm).

The Brembo GT-6 rotor weighs 17.6 lbs (355mm).

(https://blog.racetechnologies.com/2015/04/16/how-much-does-a-brembo-performance-big-brake-system-weigh-vs-o-e-components/)

The Genuine BMW E9X M3 front rotor weighs 26.6 lbs

(https://www.m3post.com/forums/showthread.php?t=135122&page=5)

Brake Bias:

Based on the official info found on https://racingbrake.com/oem-calipers/

Caliper	Front Piston	Rear Piston
ZL1/CTS-V	30/34/38	28/32
Giulia Quadrifolio	30/34/38	No retrofit available
W204 C63 AMG	34/36/38	No retrofit available
Brembo ® GT6/GT4	28/34/36	32/32
Stoptech ® ST60/ST40	26/28/30	26/26

 

Rough Bias Calculation (Based on 380mm F/R or 355mm F/R)

ZL1 bias: ~65.6% to the front

BMW E9X M3 factory bias: 65% to the front

BMW E46 M3 CSL/ZCP bias: 64.8% to the front

Brembo® GT6 (380mm F/380mm R) bias: ~61% to the front

Stoptech® ST60/ST40 (380mm F/355mm R) bias: ~65.2% to the front

More Bias Info:

ZL1 front-only setup on the Genuine BMW E9X M3 rotor (360mm) bias: ~66.5% on the front

ZL1 front-only setup on the Genuine BMW F8X M3/4 rotor (380mm) bias: ~71% on the front

ZL1 front with the Genuine BMW E9X M3 front rotor (360mm), rear with Genuine BMW E9X M3 rear rotor (350mm) bias: ~65.5% on the front

 

For A90 Supra:

Stock Front Caliper has total piston area:

2*(3.14*(40/2)^2)+2*(3.14*(44/2)^2) = ~5551

ZL1 Front Caliper has total piston area:

=2*(3.14*(30/2)^2)+2*(3.14*(34/2)^2)+2*(3.14*(38/2)^2) = ~ 5495

Our ZL1 kit keeps a very similar brake bias compared to the stock A90 Supra

(Gazoo Racing Supra GT4 uses 390 mm F/ 355 mm R)

 

Conclusion:

ZL1 Retrofit 380mm Big Brake Kit has a similar brake bias to Stoptech ST60/ST40 (380mm F/355mm R) Kit. Both kits have a similar brake bias to the stock E92 M3 brake bias or E46 M3 CSL/ZCP bias.

Rotors:

Signature Werks Heat-Treated High-Carbon Rotors

Signature Werks Heat-Treated High-Carbon rotors featured higher carbon content than regular cast iron rotors. High-Carbon materials enhance the thermal properties, friction, and noise-damping ability. (Rotor material comparison: https://trade.mechanic.com.au/news/disc-rotor-materials-g3000-g250-high-carbon-what-the-flux/). The heat-treated technology further improves the thermal resistance for track abuse.

Two Piece Floating Design with Heat-Treated Aluminum Hat

The two-piece floating design help save rotation mass and floating when braking. Internal cooling vanes option can further improve thermal properties. The rotor hat is made of 6061 heat-treated billet aluminum or 7075 heat-treated billet aluminum upon request with a hard anodized coating. This material was specifically chosen for its strength at high temperatures, as it will be in direct contact with the searing hot iron discs.

More Rotor Option:

Utilizing the Genuine BMW E9X M3 rotors (360x30mm F/350mmx24mm R). or Genuine BMW F8X M3/4 rotors (380x30mm F/370mmx24mm R) rotors.

(BMW E9X M3, F8X M3/4 applications only) 

Replacement Rotor Ring From Different Brands:

Front 380x34: Brembo® 09.7792.10/20 / 09.7792.11/21 (https://paragonbrakes.com/rotor-rings-380x34mm-pcd-241mm/)

Rear 380x28 Brembo® 09.A186.10/20 / 09.A186.11/21

(https://paragonbrakes.com/rotor-rings-380x28mm-pcd-258mm/)

Front 355x32 Brembo® 09.5759.13/23 / 09.5759.35/45

(https://paragonbrakes.com/rotor-rings-355x32mm-pcd-233mm-d50/)

Rear 355x28 Brembo® 09575927 / 09.5759.27

(https://www.racing-professionals.de/en/cast-iron-discs/548-brembo-racing-disc-355x28-09575927.html)

Bracket Adapters:

Signature Werks in-house CAD designed heat-treated aluminum brackets are machined from heat-treated 7075-T6 billet aluminum, and hard anodized, ensuring strength and durability, this alloy is one of the strongest types of aluminum available. When looking at both alloys in the “T6 condition” it’s noticeable that 7075-T6 aluminum properties feature a tensile strength that is nearly double that of 6061 T6 aluminum properties. The shear strength of 7075-T6 is estimated to be 1.5 times that of 6061-T6. 7075-T6 aluminum is substantially harder as well.

Bracket Fitment:

Every Signature Werks heat-treated aluminum brackets are 100% bolt-on with the vehicle we offer with. Zero modification requires.

Brake Pads:

Signature Werk Chevrolet ZL1 1LE Retrofit Big Brake Kit Program comes standard with Dixcel® Extra Speed Non Asbestos Organic Ceramic brake pads (https://www.dixcel.co.jp/en/pad/pad_es.html).

Dixcel® Extra Speed Brake Pads Details:

They are made for aggressive driving on the street and track day with better brake performance, high fade resistance makes for stable braking performance even during aggressive driving. The friction surface of the brake pads are scorched to improve the bedding-in process. Non-Asbestos, and non-Steel makes it environmentally friendly. 

Effective Temperature Range: 0-873 Fahrenheit.

Upgrade Brake Pads Options:

We provide Endless® MX72 pads as an upgrade option on our website. (https://endless-sport.global/us/products/pad_1a/4)

 

Other Track Brake Pads Options:

For Kits with SW 355/380mm two-piece rotors OR Stock E9X M3 rotors:

Front:

Brake pads compatible with Brembo® GT6 Calipers
Utilizing Wide Annulus Rotors (57mm radial pad depth)

Pads listed here replace the following Brembo pad part numbers:

07.9551.13
07.B314.59 (16.8mm thickness)
B6417

Ferodo DS1.11 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_1521&products_id=16302)

Ferodo DS2500 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_1521&products_id=3964)

Hawk Blue 9012 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_1521&products_id=19402

Hawk DTC 60 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_1521&products_id=13666)

Hawk DTC 70 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_1521&products_id=3962)

Hawk DTC 80 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_1521&products_id=20953)

Pagid RSL29 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_1521&products_id=14209)

Rear:

Brake pads compatible with
Brembo® GT2 Calipers

Pads listed here replace the following Brembo part numbers:

07.5146.30
07.5146.31
07.6953.9
07.8720.xx

Ferodo DS1.11( https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=12083)

Ferodo DS3.12(https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=28776)

Ferodo DS2500 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=141)

Hawk Blue 9012 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=6851）

Hawk DTC 60 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=6852)

Hawk DTC 70 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=980)

Hawk DTC 80 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=22101)

Pagid RSL1 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_85&products_id=29993)

Pagid RSL29 (https://www.zeckhausen.com/catalog/product_info.php?cPath=82_529&products_id=11137)

 

For Kits with Stock F8X M3/4 OR M2/M2C rotors:

We can use the exact front pads for Gen 6 Camaro SS 1LE, but GT2 rear pads.

Front:

Signature Werks Chevrolet ZL1 1LE Retrofit Big Brake Kit Program comes standard with Goodridge® G-Stop Stainless Steel brake lines. (https://us.goodridge.com/files/documents/USA_Car_App_Guide_2018.pdf)

Goodridge® G-Stop Stainless Steel Brake Lines Details:

Goodridge G-Stop High-Performance Brake Line Kits are direct bolt-on replacements for all of the rubber brake lines in the vehicle's brake system. To ensure proper fit and easy installation, hose ends and brake line brackets that match the vehicle's original equipment style are used for each application.  By conforming to all requirements of the Federal Motor Vehicle Safety Standard Number 106, Goodridge G-Stop High-Performance Brake lines are US Department of Transportation Certified and T.U.V approved. All Goodridge G-Stop High-Performance brake lines go through a 9-point Quality Assurance testing process that includes measuring tensile strength and the ability to contain line pressure to 3,000 pounds per square inch.

Installation Note:

1. ISTA+ or INPA bleeding process is recommended to firm up the pedal. 

Primary circuit: In the SC hydraulic control unit, air bubbles can adhere to the edges and valves, and these cannot be removed by rinsing with the brake fluid change unit. The vibrations that occur during ventilation with the diagnosis system loosen the air bubbles.

Secondary circuit: Under normal conditions, DSC does not intervene), the secondary circuit of the SC hydraulic control unit is closed so that the air it contains cannot escape when rinsing with the brake fluid change unit.

When bleeding with the diagnosis system, the return pump and the exhaust and high-pressure switching valves are activated during rinsing so that the secondary circuit is also bled.

After the exchange and repair of the following components, bleeding must be done with the diagnosis system:

- Hydraulic unit

- Master Brake Cylinder

- Components or connection lines that are located between the hydraulic unit and tandem brake master cylinder

Operations:

For the DSC8, operations 3... 7 must be performed in the order of rear right, rear left, front right, and front left.

 

For the DSC MK60, the operations are specified explicitly in the test module.

1. Connect the brake fluid-change unit and switch it on (the filling pressure must not exceed 2 bar

2. Fully rinse the brake system

3. Attach the bleeder container to the vent valve

4. Open the vent valve

5. Start bleeding with the diagnosis system with an open vent valve

6. After completing the bleeding, operate the brake pedal 5 times to the limit position; bubble-free brake fluid must escape

7. Close the vent valve

8. Remove the brake fluid change unit

A second person is required for this task.

2. Proper bedding after installation is required:

https://brakeperformance.com/bedding-in-rotors.php

We recommend getting our brake kit installed by a certified shop. 

'''FOR OFF-ROAD USE ONLY'''