Measurement and production of an Audi R8 ceramic brake for the VW Golf 4 R32 Turbo ceramic tuning brake system
The customer's request / problem:
From now on Holger drives a complete R8 ceramic brake system on his VW Golf 4 R32 - cool, isn't it?
Between the years we received the following request:
"I intend to convert my Golf 4 R32 Turbo to ceramic brakes on the front axle and on the rear axle." Thereupon our technician checked what was possible and whether we already had something suitable in our range.
The answer was:
"I just had a look - we haven't done anything yet for VW Golf 4 to Audi R8. Only for the Golf 5 series. That means we would have to make a custom-made product."
In response to this answer, the customer had the following concerns:
"Before I buy the system, however, I should know whether it would generally be possible to adapt the R8 brake 400 + 356 mm to the R32 Golf 4. Don't want to spend the money on the brake system and then have it lying in the basement. Can you manage that?"
Our answer:
"We can definitely do it, because we have already built a ceramic brake system on a VW Golf 4. The only important thing is that you have to consider converting your wheel hubs to 5x112 at the same time, as drilling around ceramic discs is very tricky."
The customer was very pleased with this answer, and a few days later we received an e-mail from him saying that he had bought the brake, an R8 (4S) VA 380 and HA 356 mm, with a separate handbrake caliper, and had already ordered the matching wheel hubs and adapters for the handbrake cables from us. And asked what the further procedure would be for his desired adapters.
There are two possibilities: either you measure the parts yourself and then send us the measurements, or do as our customer did and send us the parts so that we can measure and test them directly. Click here for more information.
No matter what, the parts, saddle and disc (axle not, as we have these in our workshop), were sent to us by box (insured), well packed of course, and measured and tested by our technician. Following this, a quotation is always sent to the customer, and as soon as this has been accepted, the adapters are added to the CAD programme. See next step.
Once everything had been measured, the adapter was transferred to the CAD programme so that our 3-printer could start work.
Our realisation / solution:
- Brake caliper from Audi R8 with separate handbrake caliper
- Brake disc from Audi R8 380mm
- For each custom-made product you will receive a matching material certificate
3-D Prototyping
After 8 hours, the part was printed and could be mounted and tested directly the next day. See, everything is correct. We were able to pass the data directly to our milling machine so that it could start with the adapters for the front axle.
Production
After Holger's approval, we now machine the brake tuning adapter for the VW Golf 4 R32 to a precise fit. Afterwards it is sent to the surface refiner.
Installation and Test
The brake tuning adapter has now returned to us from the surface tuner and we were able to test assemble everything and deliver a great brake system to our customer.
Installation pictures from Holger