'90 ZR-1 brake refurbish options

[tiegsd]

All,

I'm looking at options to refurbish (preferred) and/or upgrade my brakes (1990). She has about 57 kmi, and (as far as I'm aware) original stock rotors and calipers. I have original wheels, which I plan to keep (just got new tires for them). I'm pretty easy on my Z, don't do trackdays, just normal street driving with the occasional zip around some twisties.

options I see so far:

1. Hunt down already refurbished stock calipers and just replace my originals. This seems like the most expeditious option if I can find the right calipers. A little more expensive than refurbishing my old ones I'd think, but I expect it would save a bunch of time and aggravation.

2. Find a refurb kit and refurb my originals. My preferred option, but unfortunately I'm not seeing any kits out there through internet searches. Least expensive, but maybe not feasible due to lack of parts?

3. See if I can dig up some 96 Grand Sport calipers. It's my understanding these are direct replacements, and would add some welcome bling. Similar to option 1 above, but maybe a little more pricey, but I'm not really budget limited per se (trying to stay under $2K if possible), just not nuts about spending a ton of money if I don't have to.

4. Find someone who can refurbish my stock calipers, and send them off to get redone. I have a Corvette restomod place in town that might be willing to do it, otherwise I'd have to go hunting for a reputable mechanic. Saves me time, and I'm not that smart on brake jobs, but time (and money) spent finding a guy might be better spent learning to do it myself (I am mechanically inclined and don't mind getting dirty).

5. Find an aftermarket replacement for my stock units that work with original wheels. Most expensive, but maybe best in the long run?

I've read through a lot of the brake related posts in the forum archives, but it seems few of them address restoration of the originals. Maybe for good reason?

I plan to upgrade my brake lines to braided as well, since those are probably original and might as well while I'm in there.

Not particularly concerned with keeping everything all original. My car is a driver, lots of wear and tear.

In any event, would like to get some suggestions, thoughts, tips, alternatives if anyone is willing to offer them. Not the most experienced car mechanic, but don't mind learning, and have (or can obtain) the tools needed to do the work myself.

Thanks in advance.

[TX '90 ZR1]

Might try Lone Star Caliper. I have used them in the past. (Back when I was actually working on projects, so it's been a few years!)
They were always a good bunch to deal with. Here's their info:
Address: 11299 I-20, Canton, TX 75103
Phone: (903) 829-8400
:cheers:

[dredgeguy]

All,

I'm looking at options to refurbish (preferred) and/or upgrade my brakes (1990). She has about 57 kmi, and (as far as I'm aware) original stock rotors and calipers. I have original wheels, which I plan to keep (just got new tires for them). I'm pretty easy on my Z, don't do trackdays, just normal street driving with the occasional zip around some twisties.

options I see so far:

1. Hunt down already refurbished stock calipers and just replace my originals. This seems like the most expeditious option if I can find the right calipers. A little more expensive than refurbishing my old ones I'd think, but I expect it would save a bunch of time and aggravation.

2. Find a refurb kit and refurb my originals. My preferred option, but unfortunately I'm not seeing any kits out there through internet searches. Least expensive, but maybe not feasible due to lack of parts?

3. See if I can dig up some 96 Grand Sport calipers. It's my understanding these are direct replacements, and would add some welcome bling. Similar to option 1 above, but maybe a little more pricey, but I'm not really budget limited per se (trying to stay under $2K if possible), just not nuts about spending a ton of money if I don't have to.

4. Find someone who can refurbish my stock calipers, and send them off to get redone. I have a Corvette restomod place in town that might be willing to do it, otherwise I'd have to go hunting for a reputable mechanic. Saves me time, and I'm not that smart on brake jobs, but time (and money) spent finding a guy might be better spent learning to do it myself (I am mechanically inclined and don't mind getting dirty).

5. Find an aftermarket replacement for my stock units that work with original wheels. Most expensive, but maybe best in the long run?

I've read through a lot of the brake related posts in the forum archives, but it seems few of them address restoration of the originals. Maybe for good reason?

I plan to upgrade my brake lines to braided as well, since those are probably original and might as well while I'm in there.

Not particularly concerned with keeping everything all original. My car is a driver, lots of wear and tear.

In any event, would like to get some suggestions, thoughts, tips, alternatives if anyone is willing to offer them. Not the most experienced car mechanic, but don't mind learning, and have (or can obtain) the tools needed to do the work myself.

Thanks in advance.
Sent you a PM

[WARP TEN]

There are quite a few more modern and perhaps radical options to improve brake performance, but I used the one of the simpler approaches--albeit a long time ago. When I had my '93 in the late '90s, I felt my brake pedal feel wasn't right, a little soft. I had Marc upgrade my calipers to the newer GS calipers which he said had a bit stiffer castings than the stock ZR-1 calipers and would improve pedal feel. At the same time I replaced the stock rubber brake lines with braided ones I believe from DRM. I felt the changes improved brake feel. On the '95 I did not need to change the calipers. --Bob

[tiegsd]

Might try Lone Star Caliper. I have used them in the past. (Back when I was actually working on projects, so it's been a few years!)
They were always a good bunch to deal with. Here's their info:
Address: 11299 I-20, Canton, TX 75103
Phone: (903) 829-8400
:cheers:

Thanks. Wasn't aware of them.

[tiegsd]

There are quite a few more modern and perhaps radical options to improve brake performance, but I used the one of the simpler approaches--albeit a long time ago. When I had my '93 in the late '90s, I felt my brake pedal feel wasn't right, a little soft. I had Marc upgrade my calipers to the newer GS calipers which he said had a bit stiffer castings that the stock ZR-1 calipers and would improve pedal feel. At the same time I replaced the stock rubber brake lines with braided ones I believe from DRM. I felt the changes improved brake feel. On the '95 I did not need to change the calipers. --Bob

Rgr. This seems to be a popular option, with good results. Wasn't having much luck finding GS calipers with internet search, but not ruling it out. Did you do front and rears, and do you recall any issues with parking brake hookup?

Thanks for your response.

[Mystic ZR-1]

Another vote for Lone Star Caliper.
You can get them powder coated red!
They're the supplier of rebuilt calipers to most if not all of the Corvette parts houses.
Stainless hydraulic lines and good pads are a good idea.
Drilled and slotted 2 piece cities are good too!

[WARP TEN]

Rgr. This seems to be a popular option, with good results. Wasn't having much luck finding GS calipers with internet search, but not ruling it out. Did you do front and rears, and do you recall any issues with parking brake hookup?

Thanks for your response.

You are severely testing my memory but I believe we only did the front calipers. They do most of the work anyway.You might try Mirrock Corvette parts for the GS calipers. They are about 45 minutes east of Pittsburgh. --Bob

[tiegsd]

Another vote for Lone Star Caliper.
You can get them powder coated red!
They're the supplier of rebuilt calipers to most if not all of the Corvette parts houses.
Stainless hydraulic lines and good pads are a good idea.
Drilled and slotted 2 piece cities are good too!

That would be ideal, get my originals cleaned up, painted, and rebuilt. Def want new SS lines. Might have to give them a call. Thnx.

[tiegsd]

You are severely testing my memory but I believe we only did the front calipers. They do most of the work anyway.You might try Mirrock Corvette parts for the GS calipers. They are about 45 minutes east of Pittsburgh. --Bob

Its feeling like calling a few key players will end up the way to find out what I need to know. This thread is def helping. Thnx.

[GOLDCYLON]

It really comes down to what you want to do. The GS/CE calipers are a direct replacement and add a little bling with the correct Venus rising corvette script logo and place a pair or Baer Eradaspeeds with them and that is a great looking setup.

If you are looking for more performance look into the six piston front narrowlites made by Wilwood

[tiegsd]

It really comes down to what you want to do. The GS/CE calipers are a direct replacement and add a little bling with the correct Venus rising corvette script logo and place a pair or Baer Eradaspeeds with them and that is a great looking setup.

If you are looking for more performance look into the six piston front narrowlites made by Wilwood

I think I've realized I really just want everything looked over, replace what needs replacing, and add a little bling for now to keep the Z on the road. Don't need extra performance at the moment, although I'm definitely looking to do that in the future.

I will look around for rotors, but my originals are probably okay for now. Not gonna lie though, been drooling over a lot of brake kits and youtube vids showing C4 through C6 brake upgrades lately.

I'm thinking of looking into what AP Racing has for my long terms plans while keeping my stock setup near term. The idea would be to autocross, and maybe try some track days in the not too distant future.

[tiegsd]

All,

Appreciate all of the input.

Going with Lone Star caliper to refurb the calipers, and get them powder coated in the process.

[WARP TEN]

All,

Appreciate all of the input.

Going with Lone Star caliper to refurb the calipers, and get them powder coated in the process.

Sounds like a good approach. You might also consider replacing 30 year old brake lines with the braided stainless ones. I felt that when I did that on my '93 it improved the brake pedal feel a bit. Enjoy your ride!--Bob

[tiegsd]

Sounds like a good approach. You might also consider replacing 30 year old brake lines with the braided stainless ones. I felt that when I did that on my '93 it improved the brake pedal feel a bit. Enjoy your ride!--Bob


Thanks. Agree, perfect time to do that. Just have to find a good set.

[WARP TEN]

Thanks. Agree, perfect time to do that. Just have to find a good set.

I believe I got mine from Doug Rippie back in the late '90s but I see they still offer them--about $140--on their website. Good luck with your project. --Bob

[GOLDCYLON]

I think I've realized I really just want everything looked over, replace what needs replacing, and add a little bling for now to keep the Z on the road. Don't need extra performance at the moment, although I'm definitely looking to do that in the future.

I will look around for rotors, but my originals are probably okay for now. Not gonna lie though, been drooling over a lot of brake kits and youtube vids showing C4 through C6 brake upgrades lately.

I'm thinking of looking into what AP Racing has for my long terms plans while keeping my stock setup near term. The idea would be to autocross, and maybe try some track days in the not too distant future.

You have lots of options that you can experiment with color as well. In one of my earlier projects, I had a pair of black GS/CE calipers powdered coated red. Here is a way back Time Machine picture with some Baer Eradispeeds. :cheers:

[Jagdpanzer]

Another big brake option from Baer
19686

19687


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[tiegsd]

I believe I got mine from Doug Rippie back in the late '90s but I see they still offer them--about $140--on their website. Good luck with your project. --Bob

Great, thanks! Will check that out.

[tiegsd]

Calipers are with lonestar caliper now, going with a bright yellow powdercoat for calipers and brackets.

Thinking of some powerstop drilled and slotted rotors as well, should look a lot nicer, plus mine or worn and rusty.

Good time to check that fx3 actuators work too, and cleanup the abs sensors, and the list is growing!

[dredgeguy]

Looks like you are all set and looking forward to Carlisle. I have the Powerstop drilled and slotted rotors and they are nice.

[tiegsd]

Looks like you are all set and looking forward to Carlisle. I have the Powerstop drilled and slotted rotors and they are nice.




Good to hear, it will be nice to not have to worry about the brakes for a while, and have them looking good on top of that. I punched out the brake dust guards from my wheels as well (finally) so I'll actually be able to see everything.


Of course now that the wheels are off for a bit, I should look into wheel refinish, because, you know, while I'm in there ...

[tiegsd]

Got some stuff today.

[tiegsd]

Powder coating done.

[tiegsd]

Operation scrub the corners has begun. Made some quick progress, and my shock is yellow again (mostly). Forgot to get a before pic, but will on the next corners. Expecting lots of elbow grease to get it where I want. ABS sensor came right out, got lucky there.

[tiegsd]

Looking to get a brake bleeder kit of some kind for when I'm ready to put everything back together.

If anyone has recommendations, would be appreciated.

[Mystic ZR-1]

Dan
Get some Speed Bleeders, they make bleeding brakes a one man job.
There's nothing worse than having your Bride help you bleed brakes....
Ask me how I know...
They're bleed screws with a built in check valve.
Summit probably has them.

[HAWAIIZR-1]

Dan

Get some Speed Bleeders, they make bleeding brakes a one man job.

There's nothing worse than having your Bride help you bleed brakes....

Ask me how I know...

They're bleed screws with a built in check valve.

Summit probably has them.



100% agree. Speed bleeders on all the cars and Harleys. [emoji1360]🤙🏼 Total lifesaver!!


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[tiegsd]

Speed bleeders it is. Thanks guys!

[tiegsd]

Refurbished calipers and brackets on the way. Also got DRM SS braided brake lines coming. Like a kid waiting for christmas.

[tiegsd]

This is how they came back to me:

[tiegsd]

Now just waiting on SS brake lines from Doug Rippie Motorsports, and bleeder kit to start putting everything back together.

Will get better pics of calipers once I have everything.

[tiegsd]

Not related to brakes, but while I was just waiting around, got a thing, courtesy of Mr. Lee Gaffigan. Looks great!

[Starman]

The hot ticket that has worked well for me on the 91Z is:

96 Grand Sport calipers
Hawk HPC ceramic pads
Baer Sport drilled and slotted front rotors
Goodridge stainless brake lines
Rippie bias spring

The PBR Grand Sport calipers appear to be the same as the 96 Collectors Edition and the low line Baer and Wilwood calipers.

Had Hawk HPS pads, little bite on the street.

Baer Sport rotors don?t have the aluminum hats and are fairly reasonable.


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[tiegsd]

The hot ticket that has worked well for me on the 91Z is:

96 Grand Sport calipers
Hawk HPC ceramic pads
Baer Sport drilled and slotted front rotors
Goodridge stainless brake lines
Rippie bias spring

The PBR Grand Sport calipers appear to be the same as the 96 Collectors Edition and the low line Baer and Wilwood calipers.

Had Hawk HPS pads, little bite on the street.

Baer Sport rotors don?t have the aluminum hats and are fairly reasonable.


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Initially went looking for the 96 CE calipers, but wasn't having any luck.

Will probably upgrade the whole system at some point, but for now will be mostly stock except for rotors & hoses.

Interesting that pads make such a big difference in brake feel, I should probably see what Powerstop recommends for use with their rotors.

Wondering what made you change the bias spring?

[Starman]

ZR-1s came with the same bias spring as base cars. The larger rear tires allows more rear braking. Very common mod for our cars.


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[tiegsd]

ZR-1s came with the same bias spring as base cars. The larger rear tires allows more rear braking. Very common mod for our cars.


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Rgr, I'm not all that smart on braking systems (although getting better) yet, this little project I have going is my first foray into that world.

I thought that a spring change might be needed if I upgraded, it was a factor in my decision to stay with stock calipers if possible, didn't want to go messing with the master cylinder (for now anyway).

What spring did you use and how has the braking system performed as a result?

Also if you have pics of your setup wouldn't mind seeing it. :D

Thanks for posting!

[Starman]

Rgr, I'm not all that smart on braking systems (although getting better) yet, this little project I have going is my first foray into that world.

I thought that a spring change might be needed if I upgraded, it was a factor in my decision to stay with stock calipers if possible, didn't want to go messing with the master cylinder (for now anyway).

What spring did you use and how has the braking system performed as a result?

Also if you have pics of your setup wouldn't mind seeing it. :D

Thanks for posting!



Pictures don?t show much with the wheels on 19901


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[tiegsd]

Trying to disconnect the old brake hoses and of course they are giving me a hard time.

Can anyone confirm the correct wrench sizes for the hose to steel line coupling?

Pics attached.

[garyhugo]

When I replaced my brake hoses there was one that would not break loose regardless of the wrench. My last resort was a new pipe wrench with sharp teeth that I was able to get a good hold of the nut with and it broke loose. I was greatly relieved. There are possibly other ways to grip that nut securely enough. Just saying what worked for me.

[tiegsd]

When I replaced my brake hoses there was one that would not break loose regardless of the wrench. My last resort was a new pipe wrench with sharp teeth that I was able to get a good hold of the nut with and it broke loose. I was greatly relieved. There are possibly other ways to grip that nut securely enough. Just saying what worked for me.


Thinking I might have to do something like that, nice to know it's worked for someone before I have to resort to it.

[tiegsd]

Got 2 of 4 loose. Liquid wrenching the heck out of the others, we'll see if that helps.

[tiegsd]

Had to use a small ford wrench, but all old hoses are out. Nothing got too mangled.

[tiegsd]

Finally warm enough to make some progress on the brakes. New lines connected (not tight yet), they are definitely all longer than the originals, will have to make sure they stay clear of the wheels. Still have to clean up the front suspension, but need to move the ABS sensors out of the way first so I can get in there and scrub.

Cleaned up my mess under the car and arranged my old parts. Plan to hang on to them, but plan to get all new bolt hardware/pins/etc, looks like all available through Corvette Central. Will order this week.

In the meantime, as long as the weather holds out, will attempt to op-test the ABS sensors while I have them out of the hubs for cleaning & inspection of the sensor heads. The wiring sheath crumbled on me on three of them, guessing they are originals, the driver's front is in much better shape and looks newer. ABS fails self-test on this car since I've owned it, so would be nice to figure that out.

[tiegsd]

Finally got off my behind and tested all of my ABS sensors. The magnets all seems to be strong by just putting a small metal object up to them.

I then used the front drivers hub to check for output. The fronts sensors both gave very strong response on my multimeter, which was set to AC mV scale. Drivers front gave me roughly 300 - 400 mV, and the passenger front gave me well over that, 500 mV with an easy turn of the hub, and off scale high with a good hard spin. The rears gave much weaker response, both were around 50 - 60 mV.

Unfortunately when disconnecting the front passenger sensor the plug on the sensor end crumbled, so it will not be able to be reused.

[tiegsd]

The wheels, still drying in the paint shop.

[doctorjay61]

Wheels look great! Did a shop do them for you? I'm in NJ looking for someone to refinish mine!

[tiegsd]

Wheels look great! Did a shop do them for you? I'm in NJ looking for someone to refinish mine!


Local shop near me in West Chester, PA. Total was about $900 for the repaint, incuding strip/clean/prime/paint/clearcoat, and put new tires on (price doesn't include tires themselves, which I got separately from TireRack). Still have to get center caps, want to put black ones on.


Contact info for the shop is attached. Hansel treated me well. He gets a ton of work, and does brake calipers as well. My wheels did take a while as we went through several iterations of reburb ideas, and we agreed up front on no rush for these.

Going to pick them up here in a bit, so will post more pics in better light later.

[tiegsd]

Wheels look great! Did a shop do them for you? I'm in NJ looking for someone to refinish mine!

Thanks btw.

Whereabouts in Jersey?

[tiegsd]

Wheels are home now. Very pleased with how they look. I went with the brightest silver I could find in the pallete, they have a bit of small flake in them.

New Michelins for shoes.

Time to start putting the old girl back together.

[doctorjay61]

Thanks for the info! I will check them out! I'm in Medford, NJ (Burlington County). My in-laws are in Malvern so I'm very familiar with the West Chester area. I have a 94 so I have the a-molds on mine. There is some curb rash on both rear wheels. Would love to have them re-done!

[tiegsd]

Thanks for the info! I will check them out! I'm in Medford, NJ (Burlington County). My in-laws are in Malvern so I'm very familiar with the West Chester area. I have a 94 so I have the a-molds on mine. There is some curb rash on both rear wheels. Would love to have them re-done!


Rgr, had curb rash on mine as well. Don't think my wheels had ever been touched, clear coat was peeling, and brake dust and road grime was etched into the barrel. They looked okay from a distance, but up close really showed their age and poor condition.


They should stay looking good for a while now, and with the super thick clearcoat on the barrel, hopefully be easy to keep clean of road grime and brake dust.

[tiegsd]

Finally making progress on front end cleanup. 30 years of grime doesn't want to come off easily.

[tiegsd]

84/85 center caps fit nicely. Needed to gently tap in to ensure tabs in back engage the lip in the rim.