[s-cars] Big Black Upgrade - How To

[Greg Johnson]

BIRA response:  BIRA faded because the last three times we tried to make
parts, after spending the time and effort communicating with everyone and
then getting a quote from the machine shop (which always took too long) we
could never get enough folks to step up to plate (group buys) when order
time arrived.  After three failed attempts, we said to heck with it  (BIRA
has always been a group of volunteers and we only have so much free time to
waste).

A short history: When BIRA began, almost a decade ago, the only Audi brake
upgrades were from a NJ outfit who was reselling a Euro upgrade and they
cost almost $3K for the front brakes alone (it used 993tt calipers over
custom hats and 933tt rotors).  A group of us listers knew brakes could be
had for less than that.  Porsche had just released its new monobloc calipers
on the Boxster and they fit nicely over Audi's US A8 rotor. With a CNC'd
bracket, you had a streetable brake upgrade (Sys 1) for about about $1K.
When the Boxster S/996 monobloc appeared, we created System 3, which put
this larger caliper over the Audi's larger Euro A8 rotors (a bit "taller"
and wider).  Because the Sys3 price was with in a few hundred of Sys 1, and
it was a better brake, Sys 1 faded away.  Sys3 was a fabulous "around town"
brake and if you slotted the rotors and ran track pads, it would support all
but the most serious track folks.   When Porsche released the 996tt/GT2
monobloc calipers, a couple of club members, who were track instructors,
wanted to put it over the 996/GT2 rotors.  They also wanted it to fit under
the urS4 OEM five spoke wheel (what most members used for the snow
wheels).   It took a bit of development, but with brackets and custom hats,
System 6 was hatched.  The custom hats added $450 to the cost of the $250
brackets and this upgrade was in the $1700 range.  Pricey, but still less
than the $3K being charged by the competition.  I've said this multiple
times: Sys 6 is overkill for the street and unless you are a track
instructor, you'll never use all that Sys 6 offers.  In short, Sys 3 (about
$1K) offered all that most folks needed.

BIRA was "closed" because a handful of us were doing the whole show as
volunteers and providing parts on a group buy basis, at cost, and our wives
could not think of any reason why they should lose their houses because of
it.  We formed an association and provided an onerous contract.   Our
"business model" was simple: we have brake designs -- if you want them, you
give up the right to sue us.  If you do not want to go this route, go
elsewhere.  As I said, we were all volunteers.  We were not making any
money, so, quite frankly, we didn't care one way or the other.  The funniest
situations were created by the poor bores who forgot that we were a
voluntary club and they'd try to treat us as a business.  This list archives
will demonstrate complaints about "customer service."   Hello!!!!  A group
of unpaid volunteers do not provide customer service . . .  if you want
customer service, go buy the $3K brakes.

Since BIRA, lots of other brakes have come out and the prices went down.  I
have no idea where we would stand in today's market.  I tend to think that
Porsche monobloc based brakes for about $1K is a good deal.  Also, there has
to be a lot of used monoblocs in salvage yards these days.  BTW, we rejected
Wilwood calipers because the had to be rebuilt on fairly regular basis.  Not
so with the Porsche monoblocs.   We also chose Porsche's monoblocs over the
Porsche 993 split calipers because two piece calipers, that are held
together by bolts, flex. Monoblocs hardly flex at all. which makes for
better brake feel and modulation.

BIRA's biggest difficulty, has always been the machine shops.  They make
their money on big projects and when you want them to bid on small projects
it's very hard to get their attention.  It would take weeks to get a bid and
months to get parts made, because we'd keep getting bumped by "real"
projects.

In sum, at the turn of the century and for the next few years thereafter,
BIRA had it's day and few others offered similar value.  Things change and
volunteer projects can only go on for so long.  We've left the website up in
hopes that it can help others.   Enjoy your brake upgrades!

Greg J
BIRA.ORG