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BNE update: Medium Brake Kit Options for adding Brembos to a 240

blkaplan

50 shades of beige
300+ Club
Joined
Jul 30, 2002
Location
Rockville, MD
I figured shouldn't forget to update the OG source of all awesome things Volvo.

We just started production on a new product that will be in stock shortly.

It's a new brake kit offering for the Volvo 240 that is intended to allow for more options when using a variety of smaller wheels. We are pairing a 4 piston aluminum monoblock Brembo Calipers with 4 different p2/p80 rotors.

286x26
302x26
316x28
320x28

The calipers maintain the stock piston diameters so there is no change necessary for the master cylinder.

These calipers are OEM products and are fully built and designed to withstand the rigors of street use as they are equipped with nice dust boots so they should offer a nice and long service life between rebuilds.

This kit allows you to take 1 set of calipers and use different brackets and rotors to change your configuration.

I personally will use it to run 15's and snow tires in the winter and 16 or 17s with summer tires, in spring through fall.


https://www.bneshop.com/collections/240/products/240-medium-brake-upgrade

IMG_2334_1024x1024.jpg




We purchased a new CNC last winter and are finally getting it up and running and this is our first production run.

<iframe width="560" height="315" src="https://www.youtube.com/embed/u4S5xkocqq8" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>

<iframe width="560" height="315" src="https://www.youtube.com/embed/yOl6K5U7EYs" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>
 
hm, 320mm rotors are only 10mm smaller than the S60R ones, but will let me run 16 inch wheels and not have to use 18s...google is saying 7 pounds each for those calipers? sounds like they have aluminum housings?
Where to find 320mm 2 piece lightweight rotors? Do these stoptech ones work? 129.39038.13 and 129.39038.14?
 
hm, 320mm rotors are only 10mm smaller than the S60R ones, but will let me run 16 inch wheels and not have to use 18s...google is saying 7 pounds each for those calipers? sounds like they have aluminum housings?
Where to find 320mm 2 piece lightweight rotors? Do these stoptech ones work? 129.39038.13 and 129.39038.14?

I did some analysis, if you care about weight.

The best bang for the buck is the 302 rotors, they weigh in at 15.84. They are extremely light for the amount of area you get.

Second best is the 316mm rotor, they weigh in at 18.7lbs. That has a PVT type core versus the traditional vanes.

Those stoptech rotors could work but you would need to machine the hats to make them fit. The lug hole diameter is too small and the center bore needs to be machined larger as well. Since we are stoptech dealer,,, we could get those and modify them and supply them as bolt on if people are so intrigued. They are a tad on the narrow side though, after all that work it might be more economical for us to build a floating hat and supply the rotor side if people are so intrigued.

the Brembos are aluminum monoblock 4 piston calipers. That means they are 1 piece construction with no big steel bolts holding them together. Makes for a very light caliper for their size.
 
Great job!

Is there a specific reason to use the p80 302mm discs instead of p2 305mm discs?
 
Great job!

Is there a specific reason to use the p80 302mm discs instead of p2 305mm discs?

The answer to your question is weight.

The 316 weighs 18.7 lbs
The 305 weighs 20.46 lbs
The 302 weighs 15.84 lbs.

You could use the 305 with the 302 bracket, but at a nearly 5lb penalty per wheel penalty, why would you?

If you want something bigger, the 316 is lighter then the 305 and has a better internal cooling configuration.
 
These are the 286 versions and the second media item shows clearance in a 15" Sirius wheel

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overflow:hidden; padding:8px 0 7px; text-align:center; text-overflow:ellipsis; white-space:nowrap;"><a href="https://www.instagram.com/p/CLP0nPUnt7F/?utm_source=ig_embed&utm_campaign=loading" style=" color:#c9c8cd; font-family:Arial,sans-serif; font-size:14px; font-style:normal; font-weight:normal; line-height:17px; text-decoration:none;" target="_blank">A post shared by BNE [Kaplhenke Racing] (@beigepower)</a></p></div></blockquote> <script async src="//www.instagram.com/embed.js"></script>
 
I did some analysis, if you care about weight.

The best bang for the buck is the 302 rotors, they weigh in at 15.84. They are extremely light for the amount of area you get.

Second best is the 316mm rotor, they weigh in at 18.7lbs. That has a PVT type core versus the traditional vanes.

Those stoptech rotors could work but you would need to machine the hats to make them fit. The lug hole diameter is too small and the center bore needs to be machined larger as well. Since we are stoptech dealer,,, we could get those and modify them and supply them as bolt on if people are so intrigued. They are a tad on the narrow side though, after all that work it might be more economical for us to build a floating hat and supply the rotor side if people are so intrigued.

the Brembos are aluminum monoblock 4 piston calipers. That means they are 1 piece construction with no big steel bolts holding them together. Makes for a very light caliper for their size.

Thanks for the comparison, trying to shave weight where possible. now an additional 30mm rotor diameter vs 5lbs rotating mass is the question. I feel like for a track day car, the additional surface area would be more beneficial vs 10+lbs rotating mass
 
Nice brake setup, interested (the Cayenne Brembo setup I have is overkill deluxe).

Wondering of the calipers are easily available on my side of the pond.
 
Nice brake setup, interested (the Cayenne Brembo setup I have is overkill deluxe).

Wondering of the calipers are easily available on my side of the pond.

We can send them to you as well, we have new units in stock that are premachined.

Anything 316 and under the caliper needs a bit of clearance. The 316 clearancing is minor and can be done with a hand file. The 286 really needs something like nice mill to modify it effectively.
 
Thanks for the comparison, trying to shave weight where possible. now an additional 30mm rotor diameter vs 5lbs rotating mass is the question. I feel like for a track day car, the additional surface area would be more beneficial vs 10+lbs rotating mass

What are you comparing?

R rotors to 316?
Stock to 316?

With any of the setups you should have enough clamping force to brake hard. The question is how much hp do you have and how frequently are high temp braking events happening.
 
What are you comparing?

R rotors to 316?
Stock to 316?

With any of the setups you should have enough clamping force to brake hard. The question is how much hp do you have and how frequently are high temp braking events happening.

I'm comparing P2R 320mm rotors to the 302 mm ones. Currently making 315hp, in the shop getting returned for around 100 more right now...Has stock 240T little brakes on it right now. car is going to be a track day/autocross toy.

Local track is Portland international, so not a long high speed track, the lighter brakes seem like they would be more beneficial
maxresdefault.jpg
 
I'm comparing P2R 320mm rotors to the 302 mm ones. Currently making 315hp, in the shop getting returned for around 100 more right now...Has stock 240T little brakes on it right now. car is going to be a track day/autocross toy.

Well, I think the 302/316 brackets are the ones for you.

The beauty of them is they are flippable so you can try a 302 to start with and if you have temp issues, get the 316mm rotors, flip the adapters, and reuse the rest of the hardware.
 
<blockquote class="instagram-media" data-instgrm-captioned data-instgrm-permalink="https://www.instagram.com/p/CLaFKkIrcFb/?utm_source=ig_embed&utm_campaign=loading" data-instgrm-version="13" style=" background:#FFF; border:0; border-radius:3px; box-shadow:0 0 1px 0 rgba(0,0,0,0.5),0 1px 10px 0 rgba(0,0,0,0.15); margin: 1px; max-width:540px; min-width:326px; padding:0; width:99.375%; width:-webkit-calc(100% - 2px); width:calc(100% - 2px);"><div style="padding:16px;"> <a href="https://www.instagram.com/p/CLaFKkIrcFb/?utm_source=ig_embed&utm_campaign=loading" style=" background:#FFFFFF; line-height:0; padding:0 0; text-align:center; text-decoration:none; width:100%;" target="_blank"> <div style=" display: flex; flex-direction: row; align-items: center;"> <div style="background-color: #F4F4F4; border-radius: 50%; flex-grow: 0; height: 40px; margin-right: 14px; width: 40px;"></div> <div style="display: flex; flex-direction: column; flex-grow: 1; justify-content: center;"> <div style=" background-color: #F4F4F4; border-radius: 4px; flex-grow: 0; height: 14px; margin-bottom: 6px; width: 100px;"></div> <div style=" background-color: #F4F4F4; border-radius: 4px; flex-grow: 0; height: 14px; width: 60px;"></div></div></div><div style="padding: 19% 0;"></div> <div style="display:block; height:50px; margin:0 auto 12px; width:50px;"><svg width="50px" height="50px" viewBox="0 0 60 60" version="1.1" xmlns="https://www.w3.org/2000/svg" xmlns:xlink="https://www.w3.org/1999/xlink"><g stroke="none" stroke-width="1" fill="none" fill-rule="evenodd"><g transform="translate(-511.000000, -20.000000)" fill="#000000"><g><path d="M556.869,30.41 C554.814,30.41 553.148,32.076 553.148,34.131 C553.148,36.186 554.814,37.852 556.869,37.852 C558.924,37.852 560.59,36.186 560.59,34.131 C560.59,32.076 558.924,30.41 556.869,30.41 M541,60.657 C535.114,60.657 530.342,55.887 530.342,50 C530.342,44.114 535.114,39.342 541,39.342 C546.887,39.342 551.658,44.114 551.658,50 C551.658,55.887 546.887,60.657 541,60.657 M541,33.886 C532.1,33.886 524.886,41.1 524.886,50 C524.886,58.899 532.1,66.113 541,66.113 C549.9,66.113 557.115,58.899 557.115,50 C557.115,41.1 549.9,33.886 541,33.886 M565.378,62.101 C565.244,65.022 564.756,66.606 564.346,67.663 C563.803,69.06 563.154,70.057 562.106,71.106 C561.058,72.155 560.06,72.803 558.662,73.347 C557.607,73.757 556.021,74.244 553.102,74.378 C549.944,74.521 548.997,74.552 541,74.552 C533.003,74.552 532.056,74.521 528.898,74.378 C525.979,74.244 524.393,73.757 523.338,73.347 C521.94,72.803 520.942,72.155 519.894,71.106 C518.846,70.057 518.197,69.06 517.654,67.663 C517.244,66.606 516.755,65.022 516.623,62.101 C516.479,58.943 516.448,57.996 516.448,50 C516.448,42.003 516.479,41.056 516.623,37.899 C516.755,34.978 517.244,33.391 517.654,32.338 C518.197,30.938 518.846,29.942 519.894,28.894 C520.942,27.846 521.94,27.196 523.338,26.654 C524.393,26.244 525.979,25.756 528.898,25.623 C532.057,25.479 533.004,25.448 541,25.448 C548.997,25.448 549.943,25.479 553.102,25.623 C556.021,25.756 557.607,26.244 558.662,26.654 C560.06,27.196 561.058,27.846 562.106,28.894 C563.154,29.942 563.803,30.938 564.346,32.338 C564.756,33.391 565.244,34.978 565.378,37.899 C565.522,41.056 565.552,42.003 565.552,50 C565.552,57.996 565.522,58.943 565.378,62.101 M570.82,37.631 C570.674,34.438 570.167,32.258 569.425,30.349 C568.659,28.377 567.633,26.702 565.965,25.035 C564.297,23.368 562.623,22.342 560.652,21.575 C558.743,20.834 556.562,20.326 553.369,20.18 C550.169,20.033 549.148,20 541,20 C532.853,20 531.831,20.033 528.631,20.18 C525.438,20.326 523.257,20.834 521.349,21.575 C519.376,22.342 517.703,23.368 516.035,25.035 C514.368,26.702 513.342,28.377 512.574,30.349 C511.834,32.258 511.326,34.438 511.181,37.631 C511.035,40.831 511,41.851 511,50 C511,58.147 511.035,59.17 511.181,62.369 C511.326,65.562 511.834,67.743 512.574,69.651 C513.342,71.625 514.368,73.296 516.035,74.965 C517.703,76.634 519.376,77.658 521.349,78.425 C523.257,79.167 525.438,79.673 528.631,79.82 C531.831,79.965 532.853,80.001 541,80.001 C549.148,80.001 550.169,79.965 553.369,79.82 C556.562,79.673 558.743,79.167 560.652,78.425 C562.623,77.658 564.297,76.634 565.965,74.965 C567.633,73.296 568.659,71.625 569.425,69.651 C570.167,67.743 570.674,65.562 570.82,62.369 C570.966,59.17 571,58.147 571,50 C571,41.851 570.966,40.831 570.82,37.631"></path></g></g></g></svg></div><div style="padding-top: 8px;"> <div style=" color:#3897f0; 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overflow:hidden; padding:8px 0 7px; text-align:center; text-overflow:ellipsis; white-space:nowrap;"><a href="https://www.instagram.com/p/CLaFKkIrcFb/?utm_source=ig_embed&utm_campaign=loading" style=" color:#c9c8cd; font-family:Arial,sans-serif; font-size:14px; font-style:normal; font-weight:normal; line-height:17px; text-decoration:none;" target="_blank">A post shared by BNE [Kaplhenke Racing] (@beigepower)</a></p></div></blockquote> <script async src="//www.instagram.com/embed.js"></script>

Calipers in cue for machining.
 
very cool

Well, I think the 302/316 brackets are the ones for you.

The beauty of them is they are flippable so you can try a 302 to start with and if you have temp issues, get the 316mm rotors, flip the adapters, and reuse the rest of the hardware.

This sounds like a very cool part.
A photo would probably make the answer to this question clear, once they're complete, but for now...How does this actually work? Is it that the bracket, in one orientation, places the caliper in the right spot for the 302mm diameter rotor, then one can transpose them, from one vehicle side to the other, in order to have the caliper be placed in the right spot for the 316mm diameter rotor? Or do you actually just mount it, "inside out" on the same side of the vehicle to achieve the varying caliper orientations?

Another question - would a May ETA for the 302/316 bracket be a reasonable expectation?
 
This sounds like a very cool part.
A photo would probably make the answer to this question clear, once they're complete, but for now...How does this actually work? Is it that the bracket, in one orientation, places the caliper in the right spot for the 302mm diameter rotor, then one can transpose them, from one vehicle side to the other, in order to have the caliper be placed in the right spot for the 316mm diameter rotor? Or do you actually just mount it, "inside out" on the same side of the vehicle to achieve the varying caliper orientations?

Another question - would a May ETA for the 302/316 bracket be a reasonable expectation?

Since it's a bracket that attaches with 2 bolts, you can bolt it on in 2 directions.

One way offset the caliper in, the other offsets it out.

We are going to start machining on the 302/316 tomorrow, production will take ~2 days and then we are sending the lot out for anodizing. That takes anywhere from 1-3 weeks.

I hope these will be ready to ship before 3/15. Could be as early as March 1st.
 
Since it's a bracket that attaches with 2 bolts, you can bolt it on in 2 directions.

One way offset the caliper in, the other offsets it out.

We are going to start machining on the 302/316 tomorrow, production will take ~2 days and then we are sending the lot out for anodizing. That takes anywhere from 1-3 weeks.

I hope these will be ready to ship before 3/15. Could be as early as March 1st.

I get it now - one way of bolting it on offsets the caliper more "inward" toward the HUB, and the other way more "outward" AWAY from the hub, as is most typically seen on an OEM bracket. You rotate it 180 degrees around the part's center point between the vehicle side mounting holes.

Thanks, understood.
 
Interesting.

Are any special provisions needed for the brake hose itself? I ask because the caliper side seals with a banjo bolt and crush washer and the female end of the hose from the Cobalt / HHR is M10 X 1.00 which may be compatible with the Volvo hard lines.
 
Interesting.

Are any special provisions needed for the brake hose itself? I ask because the caliper side seals with a banjo bolt and crush washer and the female end of the hose from the Cobalt / HHR is M10 X 1.00 which may be compatible with the Volvo hard lines.

no special provision needed :)
 
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