The phenomenon is fairly common in circle track racing. A racer will spend his last penny on his engine or a new set of tires, while ignoring his brake system. Good braking just isn't as sexy as fire-breathing power, or a handling package that makes the car feel like it is riding on rails. In truth, the braking system--and its ability to stop the car quickly, consistently, and without upsetting the suspension--is vital to getting around the track quickly. This ain't drag racing after all. Unless you are racing Daytona or Talladega, you are probably using the brakes at least twice every lap to keep from wadding your car into the wall.
Racers need to consider the braking systems used by professional teams. In many cases, the higher initial cost pays for itself in short order.
Mark Davis, owner of the Carolina Motorsports Tech Center in Conover, North Carolina, recently upgraded the brakes on his Hooters ProCup car. The racing team, known as Carolina Team Concept, is made up of students from the CMTC, but the car is funded just like every other race operation. The goal at the track, just like every other team, is to win.
"We don't have the budget some of the other cars do," Davis says. "But we try to make sure we always do what it takes to win. I know a lot of guys will pinch pennies and think that as long as the brakes don't outright fail, they've done their job. That doesn't address the performance aspect of how the right brake package can help you get around the track: how light they are, how well they resist fading, how stable the calipers are. Things that help you go as fast in the last 10 laps as you did in the first 10. In my opinion, if a part can help you make the move from a Top-5 finish to a win, then it's worth some extra money."
Don Everhart of North American Race Parts provided technical support for this project. Everhart regularly advises race teams at every level on pad/rotor/caliper combinations that best suit their needs. It may sound odd, but hardware choices are actually harder for the Saturday night racer than for the Winston Cup guys. For the regular guy, outright performance and total weight aren't the only determining factors, there's also money and longevity to consider. For our needs, racing the Northern Division of the ProCup Series (Busch-type cars on short tracks), Everhart pointed us toward Alcon six-groove rotors, which are light, at just 11.9 pounds each, but should last the greater part of a season under hard use. For calipers, we chose Alcon B-Type units for the front, which are high-end pieces, but weigh in at just 6.3 pounds each. Even lighter H-Type units (4.5 pounds) were selected for the rear wheels. Performance Friction pads will do the dirty work.
"This isn't an overpowering brake system," Davis says. "But that's OK because we don't want to be hauling a bunch of weight around the track on the wheels. If the brake system is installed correctly and cooled properly, you don't need as much. That's the trick."
Both Davis and Everhart agree that the best thing you can do to ensure dependable stoppers during a long race is to put in the time beforehand. That means regular rebuilds (every four or five races), which include replacing all the seals, as well as changing the brake fluid every week. You need to keep a close watch on fluid temperatures. If you are spiking into the boiling point every week, you need to rethink your cooling system. Recirculators probably aren't necessary, but make sure your ductwork is as straight as possible and unclogged. Just like airflow to the combustion chambers, you want to provide air to cool the brakes in as straight a shot as possible.

Alcon offers options for the...

Alcon offers options for the Saturday night racers that approximateWinston Cup performance without the Winston Cup price.

Mark Davis, owner of the Carolina...

Mark Davis, owner of the Carolina Motorsports Tech Center, believesexcellent installation and maintenance habits when it comes to yourbraking system will allow you to use smaller, lightweight componentswith no dropoff in performance or longevity.

The first step is to bolt...

The first step is to bolt the hats onto the rotors. In our case, we arenot using a floating hat design.

The steel brake lines are...

The steel brake lines are routed ahead of time to make sure everythingremains below the level of the master cylinders. When bleeding thebrakes, air bubbles tend to collect at any point where the line is abovethe master cylinder, making your chances of getting the job done rightmuch more difficult.

A good double-flare tool will...

A good double-flare tool will make your life a lot easier and your brakelines a lot cleaner.

The brake lines are run along...

The brake lines are run along the chassis tubing to shield them fromdebris flying up from the track and off the engine.

Here, one of the spindles...

Here, one of the spindles is mounted in a vise to hold it steady whilethe proper locations are determined. The rotor is attached to thespindle, and the caliper is clamped on the rotor by using air pressureto engage the brake pads against the rotor. By releasing the airpressure, the caliper can be moved until the right location in relationto the rotor and spindle is found. This is a lot cleaner than trying touse hydraulic fluid.

To maintain optimum brake...

To maintain optimum brake pad contact with the rotor, the top wallinside the caliper should be .060. The proper depth is determined with afeeler gauge.

Next, we make sure the caliper...

Next, we make sure the caliper is centered over the rotor. This is donewith a dial caliper.

Now that the caliper is properly...

Now that the caliper is properly located and held in position by theforce of the brake pads pressing against the rotor (which has,obviously, been locked so that it cannot spin), we can begin measuringfor the brackets.

The bracket for the rear caliper...

The bracket for the rear caliper mount is gusseted because it must bewelded to the axle tube at a 90-degree angle.

The brackets, which have simply...

The brackets, which have simply been cut from steel plate, are tackwelded into place with the spindle, rotor, and caliper all still on thefixture.

The caliper mounting hardware...

The caliper mounting hardware is bolted and safety-wired to ourbrackets, which we have welded to the spindle. This system allows forshims to be used to readjust the calipers as needed.

Caliper location is rechecked...

Caliper location is rechecked to make sure the pads will contact therotor evenly on both sides. Notice the mounting stud in the topright-hand corner of the caliper.

Here's the setup on the rear...

Here's the setup on the rear axle.

Although lightweight, these...

Although lightweight, these four-piston calipers are well built. Theyare engineered to eliminate as much flex as possible. Features include abillet bridge to help strengthen the top of the caliper and big "beams"of material running down either side of the caliper. If you suspect yourcalipers are flexing, check pad wear. Pads that have more wear at thetop (the part contacting the outside of the rotor) than the bottom are aresult of the caliper flexing out as the pistons press the pads againstthe rotor.

A lot of race teams settle...

A lot of race teams settle when it comes to cooling the brakes by simplypointing the cooling hose at the inside of the rotor using the TLARmethod. ("That looks about right.") This is almost guaranteed to lead toinefficient cooling. The other end of the spectrum is carbon-fiber"caps" that direct cooling air from the hose into the center of therotor--nice, but expensive. You can do the same with a sheet of aluminum,a hammer, a shrinking tool, and a tig welder. It doesn't have to befancy, but the goal is to get all of the cooling air from the hose ontothe rotor and caliper. It is difficult to see in this photo, but Davishas also built a backing plate mounted to the back of the spindle tofinish the cap.

When finishing up the plumbing,...

When finishing up the plumbing, it's a good idea to leave a little slackin the line just before the master cylinders. This way, if the front endgets knocked out of joint, the brake lines aren't so tight that theypull the master cylinders off the firewall, ruining them too.