I recently completed a custom front brake kit using a set of 986 Boxster (non-S) calipers mated to 300x24mm bolt-on SVT Focus rotors.
I’m really quite happy with how they turned out, and in the process I ended up with a complete CAD design that I could, theoretically send out for quotes to local machine shops, if enough people would be interested in purchasing a set, which would mean getting at a minimum of 5 sets made to make the cost reasonable.
Fitment - They fit directly under my 16x8” Konig Dekagrams with no spacers required. The calipers stick out about 2-1/8” towards the spokes from where the factory FiST rotors sit, so you’d need about 2.25” of spoke clearance. (SVT rotors are at the same depth). I haven’t verified fit with any other wheels except my Autech 16x7” ET38 snow tires, which also fit. Some 15” wheels might also fit, but I’ve not verified any other wheel fitments. Unfortunately factory FiST wheels would not fit without spacers. There might be a different solution for that, but I haven’t had the time, money or motivation at this stage to develop that since they wouldn’t work for my setup.
It’s currently looking like I could probably get them made for between $375-400 per set. This is a bit more than you’ll see for some equivalent parts available online for other platforms, but I’m not getting the kind of volume discounts they are (or someone like Ron could get)
What the kit would include:
- 2x Brackets for adapting calipers to the Fiesta ST front hubs
- 4x Grade 12.9 Bolts for attaching the calipers to the brackets
What you would need to supply yourself:
- 1x pair of factory Brembo FRONT calipers from a base model Porsche 986/987 (2.5L or 2.7L) Boxster. Any year from 1996-2012 should work as long as they are the gray Non-S type. (The S calipers are usually red and are made for a thicker rotor and slightly different mounting) I found mine used on eBay for $300
- Optional, for under $100 you can get a rebuild kit for the calipers with fresh seals and boots.
- 2x 300x24mm rotors meant for a 2002-2004 Ford Focus SVT. These are a direct fit on the factory FiST hubs with no redrilling or messing around. Centric rotors are ~$40 ea on Rockauto, or a bit more from Tire Rack
- 4x Factory FiST caliper mounting bolts. You can probably reuse the stock bolts if they are in good shape.
All told, you could probably get all the extra bits for $500 with fresh seals, but not including your choice of brake pads, which of course you’d also need to buy separately.
Including brake pads the total price tag comes in right around $1000, comparable to budget kits like the Wilwoods, except in this case you’d get OEM quality Brembos, Porsche brake pad selections and availability (spec-Boxster) with generous pad area and inexpensive OEM rotors.
The brackets would be machined from 6061-T6 Aluminum, Hard Anodized for corrosion resistance and installed with Helicoil threaded inserts so you don’t have to deal with the downsides of threading steel bolts into relatively soft aluminum. At the moment I’ve redesigned them to reuse the stock caliper mounting bolts for ease of install instead of the ARP’s I used for my build, but could reconsider that if people would rather spend the extra coin on the ARP’s (an extra $60-70)
If you want to know all the dirty details of the development I did, there is a 5-part post in my build thread here:
https://www.fiestastforum.com/threads/feisty-the-family-car.30825/post-522405
I’m really quite happy with how they turned out, and in the process I ended up with a complete CAD design that I could, theoretically send out for quotes to local machine shops, if enough people would be interested in purchasing a set, which would mean getting at a minimum of 5 sets made to make the cost reasonable.
Fitment - They fit directly under my 16x8” Konig Dekagrams with no spacers required. The calipers stick out about 2-1/8” towards the spokes from where the factory FiST rotors sit, so you’d need about 2.25” of spoke clearance. (SVT rotors are at the same depth). I haven’t verified fit with any other wheels except my Autech 16x7” ET38 snow tires, which also fit. Some 15” wheels might also fit, but I’ve not verified any other wheel fitments. Unfortunately factory FiST wheels would not fit without spacers. There might be a different solution for that, but I haven’t had the time, money or motivation at this stage to develop that since they wouldn’t work for my setup.
It’s currently looking like I could probably get them made for between $375-400 per set. This is a bit more than you’ll see for some equivalent parts available online for other platforms, but I’m not getting the kind of volume discounts they are (or someone like Ron could get)
What the kit would include:
- 2x Brackets for adapting calipers to the Fiesta ST front hubs
- 4x Grade 12.9 Bolts for attaching the calipers to the brackets
What you would need to supply yourself:
- 1x pair of factory Brembo FRONT calipers from a base model Porsche 986/987 (2.5L or 2.7L) Boxster. Any year from 1996-2012 should work as long as they are the gray Non-S type. (The S calipers are usually red and are made for a thicker rotor and slightly different mounting) I found mine used on eBay for $300
- Optional, for under $100 you can get a rebuild kit for the calipers with fresh seals and boots.
- 2x 300x24mm rotors meant for a 2002-2004 Ford Focus SVT. These are a direct fit on the factory FiST hubs with no redrilling or messing around. Centric rotors are ~$40 ea on Rockauto, or a bit more from Tire Rack
- 4x Factory FiST caliper mounting bolts. You can probably reuse the stock bolts if they are in good shape.
All told, you could probably get all the extra bits for $500 with fresh seals, but not including your choice of brake pads, which of course you’d also need to buy separately.
Including brake pads the total price tag comes in right around $1000, comparable to budget kits like the Wilwoods, except in this case you’d get OEM quality Brembos, Porsche brake pad selections and availability (spec-Boxster) with generous pad area and inexpensive OEM rotors.
The brackets would be machined from 6061-T6 Aluminum, Hard Anodized for corrosion resistance and installed with Helicoil threaded inserts so you don’t have to deal with the downsides of threading steel bolts into relatively soft aluminum. At the moment I’ve redesigned them to reuse the stock caliper mounting bolts for ease of install instead of the ARP’s I used for my build, but could reconsider that if people would rather spend the extra coin on the ARP’s (an extra $60-70)
If you want to know all the dirty details of the development I did, there is a 5-part post in my build thread here:
https://www.fiestastforum.com/threads/feisty-the-family-car.30825/post-522405
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