Tech Tips

Pyramid of upgrades

pyramidofupgrades

Suprisingly one of the least effective upgrades (within a reasonable budget) is power. What? That’s correct. Sure if you have an unlimited budget and can turn that wheezing 6 cylinder into a 1000 HP monster you’ll pick up some significant time (and a few pairs of soiled underpants) but for the rest of us without a money tree there are more effective upgrades. 

Now read that list again. I’ve listed it in order of effectiveness. You’ll notice that YOU are at the top of that list. Remember you’re the first round draft pick for your own track team, so invest your money in yourself first! 

So lets get to it: 

Read more: Pyramid of upgrades

Raptor Brake Upgrade

upgrading ford Raptor brakes

 

Why Upgrade My raptors Brakes?

  • If you've done performance upgrades like engine and suspension mods,  Upgrading the brakes ensues you can stop or control better.
  • Bigger/more efficient brakes can handle heat better thereby reducing brake fade.
  • Bigger rotors as well as better rotor design adds for longevity, cost savings, heat capacity and shedding, andbetter clamping force.
  • Alcon Raptor Heavy Duty brakes are a bolt on upgrade.  If you can change pads, you can upgrade your brakes.

 

 RaptorKit ecom drilldown.fw

 

Shortcomings Of The FORD RAPTOR Factory Brakes? 

While stock SVT Raptor brakes are fine for stock trucks, when used in performance applications with higher than "usual"  speeds, the factory brakes aren’t sufficient. When the brakes are used, heat builds up in the system reducing efficiency.  This adds premature wear and stopping distance. Stock Raptor brakes are designed for typical drivers and not the upgraded HP, modded, enthusiastic, sporting drivers we see looking for something more out of their truck.

 

What Makes The ALcon Big Brake / Heavy duty Kits Better?

The Alcon Raptor Heavy Duty brake kit offers better all around performance. Rotors are much higher quality, calipers are stiffer and stronger, and the braking surface is increased.  Check out the stats:

 

Features  Benefit 
 Ductile Iron Calipers 

 Provide maximum strength and stiffness with high resistance to fatigue and impacts.
 15% reduction in pedal effort

 Larger/thicker rotors

 Increased brake torque and larger thermal mass.  10% reduction in disc temp rise.
 Less brake fade

 Larger high friction brake pads  

 Increased stopping power and torque

 Epoxy acrylic paint

 Maximum corrosion protection and a hot new look

 High temperatureseals

 Increased seal life and dust protection for maximum service intervals.

 

 

is the raptor kit really a Bolt on Upgrade?

If you have ever changed the tires, brake pads, or rotors on your Raptor then this upgrade will not be difficult for you. If this is your first brake job, then it may take you a little longer to do the install. The best tactic is to change one side at a time, keeping the other side intact as a visual reference. Generally, the install should take only a few hours and basic mechanic tools.

 

What Other Areas Should I Address When Performing This Install?

THis is a great time to flush your brake fluid. It should be a clear, golden color. Brake fluid traps moisture and dirt in the system and should be replaced every two to three years minimum. Have a local shop do it if your not comfortable with the procedure as it may the ABS pump to be cycled a few times to rid itself of any old fluid.  Here are some brake bleeding tips for bleeding your Raptor brake kit.

STaSIS Braking: Harnessing Your Horsepower

STaSIS Braking: Harnessing Your Horsepower

(article saved for archival purposes from Stasisengineering.com)

Engineered to provide superior response, control and pedal feel, our brake systems apply Alcon braking technology to your car, ensuring outstanding stopping power under any condition. Alcon’s race-winning technology, derived from the highest echelon of motorsport such as Formula 1 and the World Rally Championship, provides the following benefits:

  • No more fade — Higher heat absorption and dispersion for shorter stops, turn after turn.
  • No warping — Specially designed two-piece floating rotors for quiet, warp-free performance.
  • Quicker reaction time — Short consistent pedal travel can save your life in a panic situation.
  • Improved pedal feel — Firm confidence-inspiring brake pedal due to ultra-stiff calipers, differential piston sizing and stainless steel braided lines.
  • Less weight — Enables shorter stops, quicker acceleration, improved steering feel and handling.
  • Lower long-term maintenance costs — Cutting-edge design in a durable, low-cost system.
  • Compatibility and ease of installation — Compatible with ABS and traction control systems with brake bias designed to ensure ultimate gripping power; all hardware is included to ensure a quick and seamless installation.

All STāSIS products and packages installed by a STaSIS-certified dealer are backed by a factory-matching 4-year/50,000-mile warranty.


No More Fade

No more fade = short, repeatable stops, turn after turn.

Rotor Metallurgy

Braking converts the energy of the moving car (kinetic energy) to slow the Audi vehicle down. The rotor must have the ability to absorb these large amounts of heat and be able to transfer the heat to the air moving through the vanes separating the disc surfaces. The rotors are made from deep core castings with high carbon and copper content, from a casting much larger than the finished rotor. The casting is then machined to a smaller size where the material composition deep inside the casting is consistent and homogenous. The combination of the casting process and unique alloy composition results in better heat absorption and conduction.

Vane Design

STaSIS brakes use either 48 or 252 vanes, depending on application, to draw air from the center of the rotor outward. These vanes work like a pump to move cool air through the center of the rotor, taking the heat away from the rotor and cooling it before the next heavy braking zone.

Combining the highly advanced iron alloy with the efficient aerofoil vane design allows the rotor to absorb large amounts of energy (heat), then eliminate heat quickly so that it is not transferred to the calipers, pads, and brake fluid, providing consistent stoping power over multiple applications for your Audi vehicle.


No Warping

Properly designed two-piece floating rotors = quiet, warp-free performance.

Benefit of Two-Piece Floating Rotors

When brakes are applied and the moving energy (kinetic energy) is converted into heat, the rotor expands radially and axially (diameter and thickness). STaSIS uses a floating rotor that can thermally grow separate from the hat. This design is superior to a one-piece rotor—when a one-piece rotor is overheated, it gets much hotter than the hat and they expand at different rates, causing warpage or cracking.

STaSIS Floating Rotor Construction

Racers have long used floating rotor technology, but the rotors found on racecars move freely on the floating pin drive connecting the hat to the rotor, causing noise. To eliminate the rattling race rotor for our luxury Audi street car customers, we have engineered a unique noise-reducing methodology that eliminates noise but still allows for thermal expansion without running out of "float."


Quicker Reaction Time

Lowered caliper and line flex + small piston retraction = short, consistent pedal travel.

Caliper Design

STaSIS calipers are cast from one piece of aluminum. This single casting design with the cross bridges cast in place creates a very stiff unit and very little compliance during braking. Less compliance means less pedal travel because the brake fluid is only applying force to the pistons, not bending the caliper. The STaSIS design applies the maximum amount of force to the brake pads in the Audi vehicle.

Caliper Piston Seals

STaSIS brakes use ultra-high-resilience piston seals, with proprietary retraction angle shape, minimizing piston travel distance for less dead pedal travel and resulting in better pedal feel in the Audi vehicle.

Caliper Weather Seals

STaSIS brakes use long-life weather seals captured in a proprietary internal piston bore groove to provide consistent performance when moving between street applications and track applications for your Audi vehicle. The ability to retain (rather than burn off) the weather seals is unique in the industry. STaSIS brake systems are the only brakes to use weather seals in professional competition, providing longer life in full-time race duty.

Stainless Steel Braided Brake Lines

Braided lines reduce the amount of flexure in the line when the brake fluid is pressurized. Like minimizing compliance in the caliper, doing so with the brake lines provides for a firm pedal again and again. The maximum force is applied to the brake pads, not to flexing the lines.


Improved Pedal Feel

Improved pedal feel = superior driver confidence.

Minimize Compliance, Fade and Pedal Travel

Many of the benefits described above apply to improving pedal feel. Low compliance in the caliper and brake lines ensures a firm pedal. Reduced fade and ultra-high-resilience piston seals promote short and repeatable pedal travel, turn after turn.

Segmented Crescent Slots

Crescent slots provide gas relief and pad cleaning while minimizing the pedal pulsations normally associated with straight-slotted rotors or cracking issues common with cross-drilled rotors.


Less Weight

Less weight = shorter stopping distance, quicker acceleration, improved steering feel and handling

The combination of aluminum monobloc calipers, small annulus iron rotors mated to lightweight aluminum hats, and lightweight, high-strength hardware results in a STaSIS brake system weighing much less than the stock brakes in your Audi vehicle.

The weight reduction in rotating unsprung mass measures up to 14 pounds per corner, and can be felt and measured in acceleration and deceleration performance. Removing unsprung mass is the holy grail in performance. Every 1 pound reduction in unsprung mass (wheels, tires, moving suspension parts) is equivalent to 1.5 pounds in sprung mass (car chassis/body, passengers, etc).


Lower Long-Term Maintenance Costs

Cutting-edge design = durable, low-cost systems.

Longer Lasting Rotors

STaSIS brake systems cost more up front, but over time, lower replacement costs means lower long term cost over the life of the Audi vehicle.  Because our rotors can run cooler due to better heat transfer, and because they can resist warping and cracking due to floating disc design, our rotors last considerably longer than factory rotors. We have seen rotors last up to five times as long as an factory rotor after being put through heavy track use.

Advanced Rotor Metallurgy

STaSIS rotors are comprised of a proprietary alloy offering stellar performance and great longevity. This advanced metallurgy allows for uniform heat distribution, structural integrity at high thermal loads, and greater resistance to thermal shock.

Advanced Piston Seal Technology

The internal weather seal design of STaSIS calipers protects the seal from the high heat generated from high-performance braking. This design coupled with the ultra-high-resilience material ensures long-term use and protects the pistons from dirt and grime.

Differential Piston Design Promotes Even Pad Wear

STaSIS monobloc calipers are designed with four or six differential pistons. Differential piston sizing compensates for mechanical end loading by applying greater force to the trailing edge of the pad. Even pressure applied to the pad protects from tapered wear and lengthens the life of the pad. Under aggressive braking, factory calipers can flex, causing pad taper that dramatically reduces the life of the pad. The STaSIS system eliminates pad taper due to caliper flex.


Compatibility and Ease of Installation

Excellent design = compatibility with Audi factory equipment and easy installation

STaSIS brake kits are complete bolt-on systems, no fabrication required. 

Engineered Design

STaSIS meticulously evaluates every Audi vehicle to determine the proper piston and rotor sizing to provide the driver maximum control under braking conditions. The Audi stock braking system applies a larger force to the front brakes relative to the rear brakes because the front wheels do a larger amount of work during braking. The difference in front to rear braking force is called bias. STaSIS brake kits maintain brake bias close to the Audi factory components so that optimum braking is achieved and the anti-lock braking system (ABS) and traction control system continue to function properly.

Complete Kits

STaSIS brake kits are complete with all brackets, lines and mounting hardware so that your kit can be installed quickly and easily into your Audi vehicle.


Track Use

STaSIS brakes are built for use on the street. Use on the track requires an appropriate supply of fresh brake pads and brake fluid designed for track use and other maintenance. STaSIS recommends that any driver considering track use become familiar with competition brake maintenance procedures.

Turbulator or non-turbulator?

Looking to identify if you have Turbulator or Non-Turbulator rotors?  Here's how!


IMPORTANT - To identify if these are the Turbulator or Non turbulator style rotor, measure the air-gap between the rotor surfaces and the metal disc thickness.

There were TWO versions of this rotor size.  Please verify which one you are ordering.

The Non-Turbulator DIV2175X535C48 - 14mm Air Gap - 9mm surface thickness 19mm Air Gap - 6.5mm - 7mm surface thickness.
The Turbulator DIV2202X602C48 - 19mm Air Gap - 6.5mm - 7mm surface thickness

These discs are direct replacements for your Stasis/Alcon BBK.  They will bolt on and are directional so you must order a Left and a Right. We also suggest replacing your brake pads andhardware when buying new rings.  Replacing the pads at this times guarantees better rotor life and better break-in than using old pads.

Advantage Extreme discs have been engineered to produce optimum bite, thermal stability and durability in an exceptionally high strength to low weight design.  This hasbeen achieved by combining a special Alcon developed iron alloy disc with an aerospace specification alloy bell.

Identifying your STaSIS hardware kit

When replacing your STaSIS(tm)/Alcon rotors, you should also replace the hardware at the same time.  Stasis had several versions of the hardware so you will need to identify which hardware you have in order to order the correct kit.  Hardware replacement is generally good practice for any brake system, street and especially track.  However, in the case of the STaSIS assemblies, the disc springs have a tendency to flatten with age.  The fine threads in the nut & bolt are often compromised upon removal due to corrosion

STaSIS field serviceable hat

Version 1 - Field Serviceable 10-bolt hat.  This hat will have 10 perimeter holes that are not threaded.  Note that that the mating surface is flat and will often have the hardened spacer between the hat and the rotor.  Typically used in the 355mm or less field serviceable setups .

Stasis Hardware kit field serviceable

 

Version 2 - "Non Field Serviceable" 10-bolt hat.  This hat will have 10 perimeter holes that are threaded.  Note that that the mating surface has raised surfaces (highlighted in yellow)  Typically used in the 355mm or less field serviceable setups .

Buy Stasis hardware non field serviceable

STaSIS field serviceable hat Version 3 - Field Serviceable 12-bolt hat.  This hat will have 12 perimeter holes that are not threaded.  Note that that the mating surface is flat and will often have the hardened spacer between the hat and the rotor.  Typically used in the 370mm or larger field serviceable setups .

Stasis Hardware kit field serviceable

 

Version 4 - "Non Field Serviceable" 12-bolt hat. This hat will have 12 perimeter holes that are threaded. Note that that the mating surface has raised surfaces (highlighted in yellow) Typically used in the 370mm non turbulator field serviceable setups .

Buy Stasis hardware non field serviceable

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