Table of Contents

Biography 5
Acknowledgments 5
Dedication 6
Foreword 6
Introduction 7

Chapter 1: Energy Conversion 9
The Conservation of Energy 9
Where Energy Comes From 10
Friction 10
Kinetic Energy 11
Potential Energy 13
Energy Transformation 14
Energy and the Brake System 14
Calculating Brake System Temperature 15
Importance of Brake Sizing 15

Chapter 2: Tires Stop the Car 18
The First Law of Motion 18
Brake Forces 18
Tire Slip 19
How Brake Forces are Generated 20
The Mu-Slip Curve 22
Choosing the Best Tires 24
Calculating Maximum Deceleration 25

Chapter 3: Brake System Design 27
Driver Applied Force 27
Brake System Overview 28
Brake Corner Gain 33
Summing Forces 34
Overall Brake System Gain 34
Calculating Deceleration 34
Calculating Stopping Distance 34
Brake System Modifications 35

Chapter 4: Brake Balance 37
Brake Force and Corner Weight 37
Perfect Balance 38
Static Weight Distribution 39
The Second Law of Motion 39
Dynamic Weight Distribution 40
The Benefits of Perfect Balance 41
Front Brake Bias 43
Rear Brake Bias 43
Measuring Brake Balance 44
Changing Brake Balance 44

Chapter 5: Pedals, Boosters
and Master Cylinders 46
Brake Pedal Components 46
OEM Brake Pedals 47
Racing Brake Pedals 48 Brake Boosters 48
Vacuum Boosters 48
Hydraulic Boosters 50
Master Cylinders 50
Master Cylinder Selection 52
Rear Brake Pressure Reduction 54
Balance Bars 54
Proportioning Valves 55

Chapter 6: Brake Fluid 58
Brake Fluid 101 58
FMVSS116 58
Dry Boiling Point 60
Wet Boiling Point 61
Water Adsorption 61
DOT Ratings 61
Brake Fluid Compatibility 64
Brake Fluid Maintenance 64
Brake Bleeding 65

Chapter 7: Brake Lines and Hoses 69
Hydraulic Circuit Design 69
Brake Lines 70
Flare Fittings 70
Brake Hoses 71
Banjo Fittings 72
Stainless Steel Brake Hoses 73

Chapter 8: Brake Calipers 76
Hydraulic Gain 76
Caliper Components 76
Taper Wear 79
Piston Count 81
Caliper Mounting 82
One-Piece (Monoblock) Calipers 84
Two-Piece Calipers 84
Knockback 84

Chapter 9: Brake Pads 88
Brake Pad Terminology 88
Coefficient of Friction 90
Coefficient of Friction Stability 91
Brake Pad Fade 91
Friction Material Categories 92
Friction Material Chemistries 93
Friction Mechanisms 96
Brake System Break-In 97

Chapter 10: Brake Rotors 100
A Rotor Refresher 100
Rotor Terminology 101
Effective Radius 103
Rotor Sizing 103
Static Weight and Rotational Inertia 103
Rotor Cooling 104
One-Piece (Fixed) Rotors 107
Two-Piece (Floating) Rotors 107
Solid Rotors 109
Vented Rotors 110
Cross-Drilled Rotors 111
Slotted Rotors 112
Rotor Inspection 113
Thickness Variation 115

Chapter 11: Sports Car Brake Upgrade 118
The Vehicle 119
The Objective 119
Picking the Right Parts 119
Bolting Them On 121
The Results 124

Chapter 12: Racecar Brake Upgrade 126
The Vehicle 127
The Objective 127
Front Brake Upgrade 127
Rear Brake Upgrade 129
Apply System Upgrade 131
Hoses, Fluids, and Pads 132
The Results 132

Chapter 13: Muscle Car Brake Upgrade 133
The Vehicle 133
The Objective 134
Drum Brakes 101 134
Picking The Right Parts 134
Bolting Them On 135
Buttoning it Up 138
The Results 138

Chapter 14: Hot Rod Brake Upgrade 139
The Vehicle 139
The Objective 139
Front Brake Upgrade 139
Brake Pedal Considerations 140
Master Cylinder Upgrade 142
Brake Line and Proportioning
Valve Installation 142
Brake Hoses 143
Brake Fluid Selection 143
Parking Brake Installation 144
The Results 144