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> So, You want Boxster Calipers, under 15" wheels..., and you say you have 3" M struts eh?
Aaron Cox
post Oct 14 2007, 08:58 PM
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hmm... lots of people in that boat.

going to later 3.5" struts means, you A ) have to pony up for them (IMG:style_emoticons/default/tongue.gif) B ) use inserts for a heavier 911, or have your 911 units revalved for 914 weight characteristics.

So myself and craig downs sat down and did some thinking.
We wanted to achieve the sleeper look of 15" wheels, but something more modern than M calipers, A calipers, and less expensive than S calipers, AND something you can get parts for (tried getting 951/944 turbo caliper parts lately????)

so we came up with boxsters.... (NON S)
*Fairly Cost effective
*light weight
*pads are double the size
*use readily available 911 carrera rotors
*parts are cheap and available.
*the calipers can be as new as 2003....

So how do you achieve this?

pretty simple. Several mockup sessions behind our favorite mexican food place on lunch breaks.... having the parts... and having a mill.

unlike 3.5" struts, a bolt on solution could not be made to fit under 15" wheels. The 3" ears interfere with the brake pads on the calipers, and spacing them out to clear would require a bigger rotor (951?) and makes 16" wheels mandatory.

Here is what we came up with


The unsuspecting victims.... (fronts and rears.... (rears are going on soon))
Cheap. Light. Newer. Gooder
Attached Image


one of the jigs, ready to put a step into the strut.
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making a level 'step' for the adapter to lock into and a nice level/true support.
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The finished products, after removing a certain amount of material. Nice and flat and true, lots of surface area (IMG:style_emoticons/default/smile.gif)
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The corresponding step about to be cut into the adapter blocks. 6061 T6 Aluminum.
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fast forward a few to the final products
Attached Image


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Brando
post Oct 16 2007, 07:22 AM
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"Teasers" they were indeed!

They're damn hot.
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Aaron Cox   So, You want Boxster Calipers, under 15" wheels...   Oct 14 2007, 08:58 PM
Dan (Almaden Valley)   any plans on giving out the specifics..? or is th...   Oct 14 2007, 09:07 PM
sixnotfour   Are those really your shoes? Nice , patent pendin...   Oct 14 2007, 09:15 PM
KaptKaos   Are those really your shoes? For years, we hav...   Oct 14 2007, 09:21 PM
davesprinkle   Are those really your shoes? Nice , patent pendi...   Oct 16 2007, 09:43 AM
Krieger914   Very nice work, but I have to be a shit stirrer. ...   Oct 14 2007, 09:39 PM
Aaron Cox   to answer a few questions... -914 struts do NOT fi...   Oct 14 2007, 10:08 PM
Aaron Cox   Wheel fitment: We have tested the fit of 15x6...   Oct 14 2007, 10:10 PM
rhodyguy   are you building a track car?   Oct 14 2007, 10:50 PM
Aaron Cox   just overkill, and engineering excercises :P goin ...   Oct 14 2007, 10:58 PM
Travis Neff   That freakin rocks!   Oct 14 2007, 10:59 PM
rhodyguy   i see. party on. what does a set of 4 calipers and...   Oct 14 2007, 11:00 PM
Aaron Cox   i see. party on. what does a set of 4 calipers an...   Oct 14 2007, 11:05 PM
rhodyguy   cool stuff, but too rich for my blood.   Oct 14 2007, 11:11 PM
jd74914   Nice Aaron, I like it. Will there really be much...   Oct 14 2007, 11:59 PM
Twystd1   Awww Hell, I did the same thing with JB weld and ...   Oct 15 2007, 12:14 AM
Brando   Holy shnap, that shit came out good bro :clap: Ma...   Oct 15 2007, 04:03 AM
woobn8r   Nice Job, They look almost like the Boxter brake ...   Oct 15 2007, 08:50 AM
siverson   Great work!   Oct 15 2007, 10:03 AM
brer   Nice! but ugly. ;)   Oct 15 2007, 11:17 AM
Brian Mifsud   Nice! but ugly. ;) :agree: so, skippin...   Oct 15 2007, 11:42 AM
Aaron Cox   Nice! but ugly. ;) we can finish the ed...   Oct 15 2007, 12:23 PM
brer   I'm a crusader for beauty. Like Everett Rues...   Oct 15 2007, 12:35 PM
Brando   Uhhh... just noticed. I think you got the wrong ca...   Oct 15 2007, 02:25 PM
Aaron Cox   Uhhh... just noticed. I think you got the wrong c...   Oct 16 2007, 12:14 AM
Dr Evil   Great, just what I need, something else to want af...   Oct 15 2007, 09:22 PM
brer   I'd like a set of those some day. maybe we can...   Oct 16 2007, 12:45 AM
Brando   "Teasers" they were indeed! They...   Oct 16 2007, 07:22 AM
thesey914   How do the Boxster callipers compare to my 4pot Br...   Oct 16 2007, 08:37 AM
Aaron Cox   How do the Boxster callipers compare to my 4pot B...   Oct 16 2007, 10:34 AM
BKLA   Aaron - Show us the rear (not yours. fool! :...   Oct 16 2007, 08:49 AM
craig downs   I have just finished Aaron's struts and I will...   Oct 25 2007, 01:28 AM
craig downs   Holes drilled   Oct 25 2007, 01:30 AM
craig downs   Since the mounting holes are into the step I had t...   Oct 25 2007, 01:36 AM
craig downs   Using a transfer punch to mark the mounting holes ...   Oct 25 2007, 01:41 AM
craig downs   Tapping holes in the struts and checking multiple ...   Oct 25 2007, 01:51 AM
craig downs   All for now will add more later   Oct 25 2007, 01:54 AM
Aaron Cox   Here is a complete pic :) Install went great - no...   Oct 27 2007, 11:35 PM
craig downs   Here is the rest of the machining The block drill...   Oct 28 2007, 04:07 PM
craig downs   Oops on the photo above the caliper is centered on...   Oct 28 2007, 04:14 PM
craig downs   Getting ready to drill the mounting holes showing ...   Oct 28 2007, 04:17 PM
TeenerTim   How about an update? Any idea of cost? Would it be...   Jan 11 2008, 08:36 AM
craig downs   Drilling the holes Tapping the holes making sure...   Oct 28 2007, 04:20 PM
craig downs   Caliper mounted to the strut   Oct 28 2007, 04:22 PM
TVRLOTUSTR3   The brake line fittings on the caliper (Banjo) a...   Jan 12 2008, 12:59 PM
craig downs   Cutting off a little of the old mounting ears so t...   Oct 28 2007, 04:27 PM
craig downs   Sorry messed up again this is the 1st time I have ...   Oct 28 2007, 04:34 PM
craig downs   Here it is installed in the car   Oct 28 2007, 04:37 PM
Aaron Cox   waiting on a tie rod end, and a pair of bolts - an...   Oct 29 2007, 12:49 PM
andys   waiting on a tie rod end, and a pair of bolts - a...   Oct 29 2007, 12:54 PM
Aaron Cox   between 1 and 2x as big :) i dont actually know, ...   Oct 29 2007, 01:05 PM
john rogers   Would it be possible to not mill the strut mount w...   Oct 29 2007, 01:32 PM
Aaron Cox   we havent looked at a 4cyl strut.... the ears mus...   Oct 29 2007, 03:48 PM
Aaron Cox   here are more facts about the swap of calipers vs ...   Oct 29 2007, 05:32 PM
Brando   What do Boxster calipers usually run for a set of ...   Oct 30 2007, 01:31 PM
Aaron Cox   rich johnson makes a simple bolt on adapter for th...   Oct 30 2007, 04:15 PM
neo914-6   Rich's fine work: He repainted the calipers...   Oct 30 2007, 05:24 PM
Brando   What stopped you from using Boxster S calipers? Si...   Oct 30 2007, 06:08 PM
neo914-6   What stopped you from using Boxster S calipers? S...   Oct 30 2007, 06:38 PM
Aaron Cox   They stop on a dime and give ya change :) cost? m...   Jan 11 2008, 03:27 PM
So.Cal.914   Nice Aaron. :)   Jan 11 2008, 03:34 PM
spunone   WOW Aaron had shoes on ......   Jan 11 2008, 07:29 PM
craig downs   Boy do they work. We got them mounted and went for...   Jan 11 2008, 07:40 PM
craig downs   Oh the rears are a lot easier. They just require a...   Jan 11 2008, 07:48 PM
McMark   Cool, cool, cool!   Jan 11 2008, 07:52 PM
craig downs   The banjo fitting is from a 911 M caliper   Jan 12 2008, 02:48 PM
TVRLOTUSTR3   The banjo fitting is from a 911 M caliper I have...   Jan 12 2008, 06:13 PM
TVRLOTUSTR3   I take it all back, I have A calipers 3.5". I...   Jan 12 2008, 06:30 PM
daveyboybadion   So did you guys just post these on Ebay for sale?....   Jan 17 2008, 03:43 AM
Aaron Cox   nope..... alot of work. with these pictures, and a...   Jan 17 2008, 11:03 AM


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