RColt 4pots - UCF30 Rebuild, Running Gear, Weight Comparison

When looking for brakes I came across this UCF30 - a monoblock lightweight 4pot calliper used on the old V8 Lexus.
A very similar design is re-sold by TRD for the old JZ cars.






Not much info was online, so I started looking for details in 2012:
/ls400ucf20-or-ls430ucf30-front-brake.html
I later found the calliper is used on other cars as an upgrade e.g. Porsche







Japs had made a dog bone to suit the GTO rotor, which is impossible to find, so I decided to make it suit the bigger and more readily available EVO rotor. 320mm vs 310mm (plus another mm thicker).






Then I had to locate a pair, couldn't find any local so I got some from USA:
/calipers-arrived-ucf30ls430-sumitomo.html
In the mean time I was having good success with the EVO callipers. So I was in no rush.






Then it was time for a rebuild, I had to visit Lexus to get the kit.
/monoblock-rebuild-kit-04479-50130-lexus.html
It never got rebuilt till this day, well yesterday.







While that was all happening, I spent time drawing and test fitting various dog bones made out of wood: /upgraded-brake-production-resumes-money.html
Then finally I bit the bullet and passed all the work I had done to my machinist:
/lexus-ucf30-monoblock-to-ralliart-colt.html



















Took a few hours to create the finish with a flapper disc.






New Orings












New dust boots, no circlip/locking wire for these.
They just sit in the lips/groove






















I wanted to work out weights, there will be no significant gain in weights. As the calliper is lighter than stock.

EVO 5/7/8 GiroDisc 32mm thick.

















Project Mu Type HC - F110 brake pads and new PS-F110 shims.
Pad measure in at ~115mm wide and ~60mm tall.
PMu quotes it at 118.5mm wide.



















Further information - Extracted from http://mercedes-190.co.uk/topic/6698335/1/ by Ake RT:
The UCF30 caliper + pad is 10.5 LBS. It is lighter than C32 AMG Caliper but still heavier than the Aluminum Brembo for EVO II

If we look at the piston size, The UCF30 Piston is 4-pot 42.8mm all around which bigger than listed in the document link in overall (SL600/C32 is 40/44mm)

Le Klaw Bleu - Forged Build - Part II - 4G15 Strip Down

Bit slower than my usual time, but 90seconds to pull down a block...battery ran out before I took the crank out 

watch it in 1080 to appreciate a proper time-lapse

Le Klaw Bleu - Forged Build - Part I - 4G15 Oversized Valve & Porting

I have up rated springs, new keepers to match the Manley valves. Valves are 1mm oversized.
They are from a Honda that have been shortened and new keeper grooves.














































Testing the OEM springs VS after market springs.
Coil Binds
OEM........... 120lb @ 1.145"
Aftermarket... 140lb @ 0.960"



Valve lapping

B18C2 Love - Failed Master Cyclinder EG - Civic Si

NGK(Japan) DENSO        IRIDIUM POWER IRIDIUM TOUGH
BKR6EN11 K20PR-L11 IK20                         VK20

MODEL::ENGINE SIZE::ENGINE CODE::SPECIFICATION::FROM-TO::DENSO::IRIDIUM POWER::IRIDIUM TOUGH::GAP

Integra   1.8L    B18C2 V-Tec, EFI 1994-1999 K20PR-L11 IK20     VK20   1.1
------------------------
Integra   1.8L   B18C7  Type R, V-Tec 1999.1-2001.9 PK20PR-L13 IK20     VK20       1.3

------------------------------------------------------------------

I can't believe how much Honda stuff is on the Honda forums with little to no concise info.
After much digging I found some info that seemed factual.

Info from:
http://www.ozhonda.com/
http://www.hstuners.com/

So I have a Civic 92-95 = EG Si which has a 7/8" master.
Civic DX/LX/VX/CX/Si (Si non-abs) < (Civic EX = Civic Si ABS), an Si has a 9"/9.5" (pending on who you ask) rotor.
Where as EX has a 10.3" rotor and a Type R has 11.1"

There are at least four Brake Master Cylinder sizes as follows:
Civic ex/si - 7/8" (22.2250mm)
Civic others - 13/16" (20.6375mm)
Civic ABS - 7/8" (22.2250mm)
Integra - 15/16" (23.8125mm)
ITR - 1" (24.5mm)

My diameter size is 7/8.
Which matches 92-95 Honda Civic Ex or Si with diameter size of 7/8...

There are at least six models of Brake Booster as follows:
NM205V
NM230V <- Mine
NM240V
NM260V
NM280V
NM290V

Brake Upgrade - Info by http://honda-tech.com/

Hardline fittings = M10x1mm




Stock 96-00 Civic DX - This is the OEM brake system. DX knuckles, DX calipers, DX rotors.
to 96-00 EX/Si
 --Take the complete knuckle (with bearing, hub, calipers, caliper hangars, rotors, and pads and swap them onto the Civic DX.
to 90-93 Integra
 --Take the EX/Si knuckle (with bearing and hub) and bolt on the 17CL14VN 90-93 Integra calipers, caliper mounting brackets, rotors, and pads and swap them onto the Civic DX.
to 94-01 Integra
 --Take the EX/Si knuckle (with bearing and hub) and bolt on the 17CL14VN 94-01 Integra calipers, caliper mounting brackets, rotors, and pads and swap them onto the Civic DX.






46100SH4A11 = Si Model; Bore: 15/16" (92-95 Civic EG with a standard 7/8 MC then a 15/16" m/c can be fitted without needing to upgrade the booster or redo the hardlines) - 90-91 civic ex 4-door?

46100SH3A02, 46100SH3A03, 46100SH3A04, 46100SH3A05, 46100SR3003, 46100SR3013, 46100SR3033} = EX Model; Si Model;
Bore: 13/16"


















- Clean the piston










- Bleed the MC






New booster is smaller in diameter










But thicker.










It was cheaper to get a 2nd hand master and booster.  This is 15/16", slightly bigger. Plus it was described as double boosted, booster.
See more: http://www.lukekailburn.com/