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Old 12-03-2018, 10:42 PM   #1
Boggie1688
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Default 2015 WRX Brake Ducting

Winter time is here, and the list of things to do with the WRX is long. First up, brake ducts. After a lot of research, I decided to build my own solution. There is an apr solution, which seems more bling that functional. Then there is the Verus solution, which is great but expensive. I also want to retain my fog light.

SpacemonkeySTI has a write up on a DIY brake duct, which will be very similar. I will be using the lower radiator grille instead of the area next to the fog light.

Parts are as follows:
2x 3 inch aluminum flange: https://www.aircraftspruce.com/catal...uctflanges.php
10 feet of high temp ducting (not sure how much I needed; also this is way cheaper than most motorsports websites): https://www.aircraftspruce.com/catal...lickkey=846720
1x Stock OEM Lower Grille
2x eBay brake duct plates: https://www.ebay.com/itm/08-UP-SUBAR...fP3z:rk:1:pf:0
4x Breeze clamps SAE 44
Assortment of rivnuts

On the stock 2015 WRX, the lower radiator grille is blocked off on both sides. The plan is to dremel out the honeycomb, or drill a 3 inch hole. I'm undecided until I get all the pieces in front to work with.

Lower radiator grille


3 inch hole


4 inch template to represent the flange
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Last edited by Boggie1688; 12-03-2018 at 10:51 PM.
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Old 12-04-2018, 11:42 PM   #2
uofime
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Quote:
Originally Posted by Boggie1688 View Post
Winter time is here, and the list of things to do with the WRX is long. First up, brake ducts. After a lot of research, I decided to build my own solution. There is an apr solution, which seems more bling that functional. Then there is the Verus solution, which is great but expensive. I also want to retain my fog light.

SpacemonkeySTI has a write up on a DIY brake duct, which will be very similar. I will be using the lower radiator grille instead of the area next to the fog light.

Parts are as follows:
2x 3 inch aluminum flange: https://www.aircraftspruce.com/catal...uctflanges.php
10 feet of high temp ducting (not sure how much I needed; also this is way cheaper than most motorsports websites): https://www.aircraftspruce.com/catal...lickkey=846720
1x Stock OEM Lower Grille
2x eBay brake duct plates: https://www.ebay.com/itm/08-UP-SUBAR...fP3z:rk:1:pf:0
4x Breeze clamps SAE 44
Assortment of rivnuts

On the stock 2015 WRX, the lower radiator grille is blocked off on both sides. The plan is to dremel out the honeycomb, or drill a 3 inch hole. I'm undecided until I get all the pieces in front to work with.

Lower radiator grille


3 inch hole


4 inch template to represent the flange
I look forward to seeing how this progresses

I thought about doing similar but havenít looking at how tight it is, how much components were gonnna run and thinking how long it would take me to fabricate a solution I liked I decided Iíd just buy the Verus kit.
That said I havenít actually ordered yet, so if you scurry along and make this look easy maybe Iíll change my mind
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Old 12-05-2018, 01:43 AM   #3
Boggie1688
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The brake plate ducts are coming from Russia, so I don't know when they will get here. There are two big hurdles: 1. Mounting the flange 2. Routing the hoses.

Based in the verus kit, I don't think I'll have an issue routing hoses. I do want to go though the underbody panel and come out into the wheel well instead of running out the fender liner. I'm ok with cutting this panel.

The flange has alot of options. It's slightly too big for the part of the lower grille that is not cut. I have three options. 1. Mount the flange behind the grille and Dremel the honeycomb open. 2. Mount the flange behind the grille and cut a 3 inch hole out. 3. Mount the flange in front of the grille and cut a three inch hole the flange slides into.

Option one would be very clean and stealth. 2 and 3 are more aggressive in looks. 3 makes removing the bumper a little more difficult. Where as with 1 and 2 you can simply unscrew the flange and pull the bumper away.

The plan is to use rivnuts. I also want to create block off plates in case cooling is too much in colder weather.

Everything else should be here by next week. I'll start thinking about mounting the flange when I have it all in hand.
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Old 12-05-2018, 07:05 PM   #4
uofime
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Quote:
Originally Posted by Boggie1688 View Post

Based in the verus kit, I don't think I'll have an issue routing hoses. I do want to go though the underbody panel and come out into the wheel well instead of running out the fender liner. I'm ok with cutting this panel. .
Theres not a whole lot of ground clearance so going under there isnít going to buy you a ton, at least not for long....
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Old 12-05-2018, 09:53 PM   #5
Boggie1688
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USPS was not suppose to deliver today, but I found a box of flanges waiting for me. Guess Amazon forced them to deliver their packages anyway.

Here are some photos of the flange. Thicker than expected.



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Old 12-06-2018, 04:32 PM   #6
Boggie1688
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I was thinking about the duct routing today, and I realized that the j pipe might be dangerously close to where I want to route the duct. I haven't drop the undertry to confirm, but its going to be tight and its going to be hot. I did a few rips from 1-4 and took an ir temp gun to measure the temp right on the first o2 sensor. Max temp I saw was 360F. The ducting can handle 500F, with short peaks of 575F. I'm not entirely sure how hot this area of the pipe will get at the track. One possible solution is to wrap the j pipe or wrap the duct. Well see when I drop the tray. I could also copy the routing path of verus, but use some 3 inch exhuast frame clearance tubing to replace their "pancake" plastic duct. The exhaust tubing would be 3 inch to box back to 3 inch. See tubeing here: https://spintechmufflers.com/frame-c...e-priced-each/

On a brighter note, the lower grille arrive today. I bought a brand new one, because its cheap and I was too lazy to take the bumper off just to get the lower grille. Weirdly enough, ebay has them listed for $99 bucks used down to $40. Brand new I paid $38 shipped. Not sure what kinda crack these people are smoking.

I drilled the grille and drop the flanges in. It looks good. I think the flanges will have to mount in the front to hide the dirty cuts from the hole saw. Nothing you can do about it, its just how the plastic melts/cuts. The flange still needs some cutting to help it sit better into the grille, and not block the clips from the bumper. As for the clamp, I wish there was enough material for the entire width of the clamp but I think I'll be fine. Hopefully once the flange is cut to fit, it sits a bit further into the grille.

I'll post up photos after I've ground the flange to fit, painted them, and secured them with rivnuts. After that, we wait for the duct and caliper back plates to arrive.

Here are some photos.

Getting a rough idea of where I want the flange to sit on the grille.









Last edited by Boggie1688; 12-06-2018 at 04:45 PM.
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Old 12-06-2018, 04:34 PM   #7
Boggie1688
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More photos of the positioning of the flange. Nasioc won't let me have 10 photos per post.





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Old 12-06-2018, 04:35 PM   #8
Boggie1688
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Cutting the grille and dropping in the flange. Note the areas where the flange will need to be cut to clear the recesses needed to mount the lower grille.








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Old 12-07-2018, 10:18 AM   #9
IronmanDaremo
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Looks good!
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Old 12-10-2018, 11:55 AM   #10
Taco Man in HD
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Very cool! I'm looking to borrow some of those parts to do something similar from my BRZ fog light holes. Nice work!
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Old 12-12-2018, 07:07 PM   #11
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Quick update.

I borrowed an angle grinder from a buddy, and started working on grinding the flange to the right size. Pretty easy work. I used 100 grit, then 220 grit to smooth out the flange after using the angle grinder. Once I had the flanges cut down to the right size, I started working on the mounting holes.

I wanted a symmetrical set of mounting points so I could flip a block off plate on the lower half or upper half of the inlet, but based on the cuts on the flange this was not possible. I settle on 3 points based on the honeycomb pattern and where I had flange to drill. I used a small bit to drill the flange, then mounted the inlet onto the lower grille and used the predrilled flange as a guide to drill the grille. Finally I widened the holes using a large bit that was selected to fit my rivnut.

I had an issue with the rivnut tool not clearing the honeycomb pattern on the grille. I used a dremel to remove enough material to let the tool full sit down into the grille. Also on one of my passes to widen the hole on the grille, my bit walked ever so slightly. I ended up having a rivnut that wouldn't hold in place. I used some super glue, and it is holding just fine. The rivnust don't keep the flange from "falling out" of the grille, they are just there to help hold block of plates. After that, I decided adding super glue to the rear of all the rivnuts would not hurt.

Finally painted the inlet ducts and mounted them onto the grille. I still got to make a trip to the store to buy some M3x0.5 hardware, but that is not a big deal. The duct still is on back order, not sure when I'll see that. The brake plates have shipped and already left russia. Lastly, I'm still mulling over my duct temperature issue, but I think that might be a problem for when I have duct to actually work with.

Here are the photos:










Last edited by Boggie1688; 12-13-2018 at 03:54 PM.
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Old 12-12-2018, 07:09 PM   #12
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Old 12-12-2018, 07:09 PM   #13
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Last edited by Boggie1688; 12-12-2018 at 07:13 PM. Reason: Double post wrong photos.
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Old 12-12-2018, 07:18 PM   #14
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Old 12-12-2018, 07:46 PM   #15
JRowland
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Cool project! Looks like itís coming along great.
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Old 12-14-2018, 10:32 AM   #16
IronmanDaremo
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When are you going to start fabricating them for sale?
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Old 12-14-2018, 11:24 AM   #17
Boggie1688
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Quote:
Originally Posted by IronmanDaremo View Post
When are you going to start fabricating them for sale?
I guess if it is something someone wants, I'm happy to help make one for them. Not sure if they want me to supply the entire kit or if they want just the grille. If anyone is interested, they can shoot me a PM and we could work something out.

On another note here is a photo of the inlets with hardware. I selected a black oxide screw with a hex head. I think it looks nice. I also ordered up the block off plates, and they should be here early next week. I'm excited to get those on and see how it looks too.

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Old 12-14-2018, 02:30 PM   #18
cdigerlando
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Looks awesome!
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Old 12-14-2018, 02:36 PM   #19
Veritas1286
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love it. can't wait to see the final setup
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Old 12-16-2018, 12:22 AM   #20
Boggie1688
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Another quick update.

Aluminum discs arrived. I ground two of them down to match the intake flange. One of them was slightly rotated when I drilled the holes, and I think there may be some interference once the bumper is on. I'll test fit and grind as necessary when doing the duct install. The block off plates should have been drilled the same time the ducts were done, would have been a smarter step but hind sight is 20/20.

I had to use some wood blocks to shore up the plate to keep it from vibrating back and forth when grinding them.

I actually had a second set of plates that I was going to cut 1.5 inch holes. The idea was to be able to swap plates if the brakes were being over cooled at the track. This would give me three "modes": 3 inch intake, 1.5 inch intake, and fully closed. However, my stupid bit wobbled and created a terrible mess. I only have one plate left, so that idea is out the window. I can't bring myself to pay 5 bucks for the disc and another 5 to ship it. Damn I'm a cheap bastard. I knew that drill chuck had a bad runout and I still went for it. On top of all of this, I had a new chuck on order and it arrives in 3 days too...kicking myself bad.

Ducts have shipped and should be here end of next week. I think the rotor backing plates should arrive sometime around then too. Given the holidays, I don't think I'll be touching back on this project till after Christmas.

Photos below:





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Old 12-22-2018, 12:56 PM   #21
Boggie1688
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Hose arrived. Just waiting on the rotor plates now.
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Old 01-13-2019, 11:07 PM   #22
Boggie1688
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Back plates are lost somewhere... UGGGH.

If lambert was only still making these..... Will try to order another set.
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Old 01-23-2019, 09:39 PM   #23
Boggie1688
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Well, brake ducts from Russia turned out to be a bad idea. Actually, I think USPS just lost the package. In any case, ebay refund my full purchase price. I ordered some ducts online at double the cost but they actually showed up 5 days later. Go figure.

The ducts seem decent, they use a aluminum spacer to push the duct away from the hub, otherwise it would hit the hub near the lower mounting hole. The ducts also come with some rubber edge guard applied to protect the abs sensor wire.

Here are photos of me taking the rotors of and installing the backing plate. Glazed pads thrown in for fun. Smooth as glass, you can rub the two pads together and it slides like butter.










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Old 01-23-2019, 09:44 PM   #24
Boggie1688
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Some more photos. Grease in the tie rods look like they boiled. Boot seem OK. Monitor and replace as needed. Also installed the grill and started routing the duct on the passenger side.










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Old 01-23-2019, 09:48 PM   #25
Boggie1688
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Just a couple more photos of the routing, and the grill. The undertray was cut in two spots for the passenger side, a large cut inside the fender area and another rearward of the intake tube. Its tight as hell. Even tighter when you are trying to keep the fog lights. Also a real pain to tighten down the clamp to the flange and then try to put the bumper on. All worth it!!!

I ran out of hose, so I have more on order. I also have some edge protector order to line some of the under tray that was cut.






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