urq G60 brake conversion

[ejfluhr@austin.ibm.com (Fluhr)]

Gang,

This weekend I installed a set of G60 calipers on my urquattro.  It
was perfect timing, too, as I was down to 1/16" of an inch on the old
pads.  Total cost for the conversion ran something like this:

1 pair G60 calipers from junkyard                 -  $40
1 pair KVR carbon fibre brake pads                -  $85
1 pair Ate Powerdisc rotors from Adirondack       - $104
1 set of 4 stainless steel brakes lines from GPR  -  $50
caliper rebuild kit (seals for 2 calipers)        -  $15
2 guide pin boot kits                             -  $16
1 bottle Castrol LMA brake fluid                  -   $5
Silver high-temp spray paint                      -   $5
Requisite donations of human skin & blood         -  n/c  (no charge)
                                                    ----
                                         Total      $320 


I also bought a sandblasting gun ($20) and a set of flare-end metric
wrenches ($28) for the job, but I don't count tools as part of the total.

The job went fairly smoothly, and each caliper assembly bolted right
into place.  As has been documented, a small piece of each front brake
heat shield had to be cut off, but the dremel and some touch-up paint
made quick work of that.  The only real difficulty I had was nearly
wrecking the left rear brake line trying to get it off with an open-end
wrench.  A trip to Sears and a set of flare-end wrenches later, I was
able to separate the lines without further damage (by a gratuitous
offering of some more skin).  After bleeding the brakes, I took
the car out for some gentle driving and the brakes seemed OK.

Now, for those of you who have completed the G60 conversion on your
urquattro without changing the master cylinder, how significant
was the increase in pedal travel before the brakes started to grab?

As it stands now, the brake pedal drops several inches (at least it
feels to be that much, but I have not measured it) before engaging the
brakes.  I hope that some of the problem is residual air in the system,
and will bleed the brakes again in a few days.  I expected some
increase in pedal travel, but not this enormous difference I have
now.  I would appreciate any feedback from those of you who have
done this conversion about your thoughts of before-and-after pedal
feel.

Thanks,
Eric
'85 CGT, '82 urq
---
Eric J. Fluhr                                Email:  ejfluhr@austin.ibm.com
High End Processor Design                    Phone:  (512) 838-7589
IBM Server Group                             Austin, TX