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Old 10-20-2010, 08:32 PM   #1
wildfrisco
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Default Mazda 3 OEM Big Brake Kit: 60-0 mph In 89 Feet w/Videos!

Since no one really pays attention to my posts anyway I'm going to keep track of my little brake project here LOL. This log is for a "OEM big brake kit" conversion: Larger Mazdaspeed 3 front and Mazda 5 rear brake components on a Mazda 3s.

12/26/11 Video:

Done at sunset (lol), there were 3 attempts. Result stopping from 60 mph was 89 feet and this time was conducted on a lot.

Mazda3 OEM Big Brake Kit pt. 2

12/25/11 Video:

Dark & grainy video showing my third attempt to stop from 60 mph. Result was 93 feet 2 inches, an improvement of 19 to 25 feet over stock. The first two attempts were in the same area but not on video, yielding 93 and 92 feet. Will get a better video.

Mazda3 OEM Big Brake Kit pt. 1

__________________________________________________ __________________________________________________ __
Subjective Log:

So I've had the OEM BBK for months now. It took at least 4 days of driving to get them to bed properly or have them working like factory Mazda brakes should feel. This is a mixture of brand new aftermarket rotors front and rear. Installed slightly used OEM Ms3 pads up front which were sanded down a bit, and brand new aftermarket Akebono Euro ceramic pads in the rear.

In the last two months I've finally started to drive and brake much harder and let me tell you, the difference in braking performance and inspiring confidence is phenomenal. Now I'm trying to decide which mod is the best so far: The Koni FSD's or OEM BBK. I don't have any hard numbers or data before and after, but for example I could be flying at ~105 mph, hit the brake for 1 second and be doing 75 mph. Or about 95-90 mph back down to 65 in about a second whereas before it usually took several seconds. But it also feels much beefier, like it actually has more stopping power or braking capacity. With my original setup, braking performance was definitely acceptable but in panic stops I always felt like they were more fragile and already at their limit. I don't like close calls. I also suspect that after some spirited driving the rotors are cooler (not cold, just not as hot) than with my original Mz3 brakes. Unfortunately I don't have any numbers to back that up, just what my foot/finger/butt dyno tells me. And I don't have to worry about performance on cold mornings or embarrassing noises like you would with an aftermarket setup because it's still excellent as a stock Mazda system should respond and silent like most factory setups, just much more powerful and confidence inspiring.

The shortest documented 60-0 mph stopping distance I've seen for a stock 2.3 liter is 112 feet, which is already excellent and same as a 1st gen Mazdaspeed 3. This was a fully loaded Grand Touring model, heavier automatic transmission, and standard larger/heavier 17" snowflake wheels. Other auto magazines have averaged 118' which is still good. The average car, ~125-130'. Mazda RX-8 and Miatas are ~111'. Porsches and lesser Corvettes are ~103-108' I think. The Corvette ZR-1 with the $10K ceramic brakes is ~97'.

I have a lighter Touring model, lighter manual transmission, lighter wheels/tires/lug nuts (lol) but heavier rotors. I really wonder where similarly setup Mazda 3s/2.3 liters sit in braking performance with this combo and a decent suspension. The crazy thing is there's still room for improvement while retaining factory driveability and a near-stock look. Lighter 2-piece rotors and aftermarket pads for example.

If you enjoy spirited, competitive driving, late braking, or canyon runs this is definitely worth the price of admission (~$950) because it adds that much more performance and safety without many compromises (except for the dustier front wheels)!

__________________________________________________ __________________________________________________ _
Other OEM BBK how-to's, pics, and info threads:

Wild Weasel's HOWTO: Install Mazda3 Brake Pads, Rotors, and Lines-
http://www.wildweasel.ca/HowTo/Auto/...keInstall.aspx

Mazda3 to Mazdaspeed3 front caliper conversion-
http://www.mazda3forums.com/index.php?topic=143970.0

Speed3 Brakes (rotors and calipers) on a 3-
http://www.mazda3forums.com/index.php?topic=113486.60

HOW TO: Install Mazdaspeed3 OEM Front Brakes For 2.0L Owners-
http://www.mazda3forums.com/index.php?topic=189424.0

Big Brake Conversion on 2.0L-
http://www.mazda3forums.com/index.php?topic=188979.0

Mazda 3 Rear Brake Upgrade: Using Mazda5 brakes-
http://www.mazda3forums.com/index.php?topic=179640.0
http://www.mazda3forums.com/index.php?topic=179450.0

Alcon Mazdaspeed 3 2-piece Brake Rotors-
http://www.mazda3forums.com/index.php?topic=180848.0
http://www.proracestore.com/index.ph...ducts_id=27733
http://www.proracestore.com/index.ph...ducts_id=27734
http://performanceparts.longobrother...ducts_id=27733
http://performanceparts.longobrother...ducts_id=27734

Other useful brake threads:

Grassroots Motorsports Step-by-Step Brake Tech For 2008 Mazdaspeed 3-
http://grassrootsmotorsports.com/pro...-mazdaspeed-3/

How-to Guide Rotor, Brake Pad, and BrakeLine install-replacement (FRONT - REAR)-
http://www.mazda3forums.com/index.php?topic=32297.0

Mazdaspeed 3 Brake Pad Guide (whats currently available)-
http://www.mazda3forums.com/index.php?topic=96219.0

List of all known Mazda 3 Brake options-
http://www.mazda3forums.com/index.php?topic=32807.0

__________________________________________________ __________________________________________________ _
Ordering & Price Log:

Fri 10/15 - Ordered rear Mazda 5 calipers from a dismantler for $90 shipped ($35 + $35 + $20 shipping) off a 2008 w/4,200 miles on it.

Wed 10/20 - Ordered front and rear Mazdaspeed 3 calipers from a dismantler for $185 shipped ($40 + $40 + $40 + $40 +$15 shipping) off a 2009 with unknown mileage.

Wed 10/20 - Ordered rear R1 Concepts Premium Series (Centric) slotted Mazda 5 rotors from R1 Concepts Inc. for $142.03 shipped, tax, & discount ($130 + $12.03 tx). Had to specify Centrics since the sales guy stated the Premium Series rotors on their site aren't Centrics.

Thur 10/21 - Ordered front Akebono ProACT [ACT1044] and 2 sets of rear Akebono Euro [EUR973 & EUR1095] ceramic pads from RockAuto for $199.68 shipped ($55.79 + $66.79 + $66.79 + $10.31 shipping). Two different rear pads; didn't want to get stuck without the correct part. Ordered both. Update - The front ACT1044 pads are for non turbo Mazda 3's!

Fri 10/22 - Ordered front Mazdaspeed 3 DBA 4000 Series rotors, 1 quart of ATE Type 200 Amber brake fluid, & Goodridge G-Stop brake lines from Tirerack for $367.84 shipped ($208 + $12 + $118 + $29.84 shipping).

Fri 10/22 - Received front and rear Mazdaspeed 3 calipers from dismantler.

Mon 10/25 - Received rear Mazda 5 calipers from a dismantler.

Mon 10/25 - Received rear R1 Concepts Premium Series (Centric) slotted Mazda 5 rotors from R1 Concepts Inc.

Mon 10/25 - Received front Mazdaspeed 3 DBA 4000 Series rotors, ATE Type 200 Amber brake fluid, & Goodridge G-Stop brake lines from Tirerack.

Fri 10/29 - Received front Akebono ProACT and rear Akebono Euro ceramic pads from RockAuto.

Sat 12/11 - Finally frickenly installed the Ms3/Mz5 rotors, calipers, brake pads, Goodridge ss braided brake lines, and bled the brakes. Will update.

__________________________________________________ __________________________________________________ _
Picture Log:

Car on jackstands and doing a test fit:


Front test fit close-up:


Left - Mz3 OEM front caliper. Right - Ms3 OEM front caliper:


Mz3 front wheel with Ms3 OEM calipers, brackets, + pads & aftermarket rotors:


Clearance of Ms3 front brake components, stick-on weights, & 16" Mz3 wheels:


Another pic of front Ms3 brake components:


Mz3 rear wheel with Ms3/Mz3 OEM calipers + aftermarket pads, Mz5 OEM brackets, & Mz5 aftermarket rotors:


1st side view with OEM BBK:


2nd side view with OEM BBK:


Attaching two additional pictures: The first chart for bragging rights, the second to help visualize shared parts (rotors). Maybe someone can check them for accuracy:

Before & After chart:


Shared rotors across different models:


__________________________________________________ __________________________________________________ __
Misc Aftermarket Rotor Question:

How many of you are interested in lightweight/high performance 2-piece brake rotors? They've got enough interest for Ms3 & Mz3 front + rear rotors, but not enough yet for Mz5 rear rotors (besides me). We need 4 others to get Mz5 rear 2-piece rotors developed. Check out the GB GIRODISC thread and let us know!

GB GIRODISC 2 Piece Floating Rotors F&R for MS3 & MZ3-
http://www.mazda3forums.com/index.php?topic=184077.0

GI GIRODISC 2 Piece Floating Rotors F&R - MS3 & MZ3-
http://www.mazda3forums.com/index.php?topic=180161.0



Attached Images
File Type: jpg Mz3 OEM BBK gains 2.JPG (5.0 KB, 42 views)
File Type: jpg Ms3 Mz3 Mz5 rotor chart 5.JPG (18.1 KB, 34 views)
File Type: jpg Mz3 OEM BBK gains 2.JPG (5.0 KB, 35 views)
File Type: jpg Ms3 Mz3 Mz5 rotor chart 5.JPG (18.1 KB, 34 views)
File Type: jpg Mz3 OEM BBK gains 2.JPG (5.0 KB, 34 views)
File Type: jpg Ms3 Mz3 Mz5 rotor chart 5.JPG (18.1 KB, 34 views)
__________________
Hypertech MESPP, Aasco lightweight flywheel, Medieval lightweight pulleys, 60mm throttle body, track pipe, Cosworth air filter, OEM BBK (Ms3 front & Mz5 rear brakes), Endless pads/DBA rotors, Koni FSD, OEM '04-06 16" Mz3 alloy wheels, staggered Continental ExtremeContact DW (225/50/16 front & 205/55/16 rear), Morimoto/Xtreme/Lamin-x HID 5,000K headlights & 4,300K fog lights, OEM LED tail lights, OEM leather seats, OEM JDM leather armrest, Eneos 5W-20, Amsoil 75W-90 GL-4, ATE Super Blue
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Old 10-20-2010, 08:35 PM   #2
halo0
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

Interesting. What rotors are you using?
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Old 10-20-2010, 08:42 PM   #3
wildfrisco
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

[quote author=halo0 link=topic=181165.msg3834266#msg3834266 date=1287621312]
Interesting. What rotors are you using?
[/quote]

Originally was going with plain Centric Premiums all around. But since TireRack seems to have a good deal for DBA 4000 Series rotors, I'm going with those for the front and R1 Concepts Inc/Centric Premium slotted rotors for the back.
Attached Images
File Type: jpg IMG_7021edited.JPG (512.1 KB, 35 views)
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File Type: jpg IMG_7029edited2.JPG (614.4 KB, 16 views)
File Type: jpg IMG_7031edited.JPG (521.9 KB, 19 views)
File Type: jpg IMG_7021edited.JPG (512.1 KB, 17 views)
File Type: jpg IMG_7019edited.JPG (400.4 KB, 17 views)
File Type: jpg IMG_7029edited2.JPG (614.4 KB, 16 views)
File Type: jpg IMG_7031edited.JPG (521.9 KB, 19 views)
__________________
Hypertech MESPP, Aasco lightweight flywheel, Medieval lightweight pulleys, 60mm throttle body, track pipe, Cosworth air filter, OEM BBK (Ms3 front & Mz5 rear brakes), Endless pads/DBA rotors, Koni FSD, OEM '04-06 16" Mz3 alloy wheels, staggered Continental ExtremeContact DW (225/50/16 front & 205/55/16 rear), Morimoto/Xtreme/Lamin-x HID 5,000K headlights & 4,300K fog lights, OEM LED tail lights, OEM leather seats, OEM JDM leather armrest, Eneos 5W-20, Amsoil 75W-90 GL-4, ATE Super Blue
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Old 10-20-2010, 08:47 PM   #4
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

How much larger of a rear rotor will you need with the Mazda5 rear calipers? What are you doing with the front?

Do you know if the 5's calipers attach using the same bracket or do you need new brackets too?
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Old 10-20-2010, 08:54 PM   #5
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

[quote author=halo0 link=topic=181165.msg3834285#msg3834285 date=1287622037]
How much larger of a rear rotor will you need with the Mazda5 rear calipers? What are you doing with the front?

Do you know if the 5's calipers attach using the same bracket or do you need new brackets too?
[/quote]

You will need Mazda 5 rear rotors and someone stated they're 0.9" or 2.2 cm bigger. For the front I'm utilizing Mazdaspeed 3 calipers and associated rotors.

The Mazda 5 rear caliper brackets will be needed. They're usually included when you buy caliper sets from dismantlers. Ask to make sure. You can use them to mount Ms3, Mz3, or Mz5 rear calipers. Ms3 and Mz3s (2.3 liter) rear calipers are the same. The piston bore on the Mz5 & Mz3i (2.0 liter) rear caliper is about 19mm smaller in diameter than the Ms3/Mz3 rear calipers.
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File Type: jpg IMG_7013edited.JPG (55.2 KB, 20 views)
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File Type: jpg IMG_7013edited.JPG (55.2 KB, 12 views)
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File Type: jpg IMG_7018edited.JPG (452.4 KB, 14 views)
File Type: jpg IMG_7008edited.JPG (476.3 KB, 17 views)
__________________
Hypertech MESPP, Aasco lightweight flywheel, Medieval lightweight pulleys, 60mm throttle body, track pipe, Cosworth air filter, OEM BBK (Ms3 front & Mz5 rear brakes), Endless pads/DBA rotors, Koni FSD, OEM '04-06 16" Mz3 alloy wheels, staggered Continental ExtremeContact DW (225/50/16 front & 205/55/16 rear), Morimoto/Xtreme/Lamin-x HID 5,000K headlights & 4,300K fog lights, OEM LED tail lights, OEM leather seats, OEM JDM leather armrest, Eneos 5W-20, Amsoil 75W-90 GL-4, ATE Super Blue
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Old 10-20-2010, 08:59 PM   #6
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

So the 5 has a bigger rotor and a smaller caliper?

Why would you use a 5's calipers on the rear if your stock ones would work?

Sorry for all the questions but I really want to do a brake upgrade next summer.
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Old 10-20-2010, 09:17 PM   #7
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

[quote author=halo0 link=topic=181165.msg3834292#msg3834292 date=1287622745]
So the 5 has a bigger rotor and a smaller caliper?

Why would you use a 5's calipers on the rear if your stock ones would work?

Sorry for all the questions but I really want to do a brake upgrade next summer.
[/quote]

From what I've been reading here, the Mz5 has bigger rear rotors. The external dimensions for the rear calipers are roughly if not identically the same. It's just that internally the piston bore is smaller for the Mz5 and Mz3i (2.0 liter) rears.

I'm not using the rear Mz5 calipers on the rear, just the brackets. I bought the whole caliper set because it was cheaper that way. $35 w/~$10 shipping per corner for used calipers, brackets, and bolts from the dismantler . Compare that to ~$104 per from the dealer or ~$71 each from online retailers, just for the bracket.

Yeah this is going to be fun since IMHO the 2.3 liter Mazda 3 already stops well. According to Motor Trend's shootout: 60-0 mph in 112 feet in a loaded GT trim and heavier automatic transmission, already equal to a Mazdaspeed 3!
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Hypertech MESPP, Aasco lightweight flywheel, Medieval lightweight pulleys, 60mm throttle body, track pipe, Cosworth air filter, OEM BBK (Ms3 front & Mz5 rear brakes), Endless pads/DBA rotors, Koni FSD, OEM '04-06 16" Mz3 alloy wheels, staggered Continental ExtremeContact DW (225/50/16 front & 205/55/16 rear), Morimoto/Xtreme/Lamin-x HID 5,000K headlights & 4,300K fog lights, OEM LED tail lights, OEM leather seats, OEM JDM leather armrest, Eneos 5W-20, Amsoil 75W-90 GL-4, ATE Super Blue
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Old 10-20-2010, 09:27 PM   #8
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

[quote author=WildFrisco link=topic=181165.msg3834301#msg3834301 date=1287623875]
I'm not using the rear Mz5 calipers on the rear, just the brackets. I bought the whole caliper set because it was cheaper that way. ~$104 per bracket from the dealer to ~$71 each from online retailers. I bought used caliper sets which include brackets and bolts for $35 w/~$10 shipping each.
[/quote]

Cool, that's what I was hoping you were going to say.

Did you source your MS3 front calipers from the same place you got the mz5 calipers? Cost?

I was talking to a guy at a show this summer who had a wrecked speed and I was trying to get him to let me buy the brakes but he wasn't sure what he was gonna do with it yet.
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Old 10-21-2010, 08:57 AM   #9
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

In the process of doing all this, I would suggest you get a set of Goodrich stainless brake lines. Once done, you'll be astounded at the difference from your stock braking.
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Old 10-21-2010, 12:37 PM   #10
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Default Re: Mazda 3 OEM BBK Upgrade Personal Log

What pads are you running now?

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