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Discussion Starter #1 (Edited)
Long story short, I got this E63 M6 a couple of months ago, took it to the track and have found out the brake system fade pretty fast, I can feel the brake start to feel spongy about a lap two. The car is also a kind of too heavy and having a hard time into the corner. I knew carbon ceramic brake is the way to go so I did some research on Internet and found @Tim_1 has done this before. I would like to post some more information so other people can take this as a reference in the future.

Original post from Tim_1: F80 Bmw ceramic brake kit on e60 m5

You will need to do the following works in order to fit F80 ccb on E60

1, Get a F80 carbon ceramic brake system.
2, Get customize built new caliper brackets to replace old one so it can fit on E60/E63 suspension.
3, Modification on the rear rotor hat to adopt E60/E63's parking brake.
4, Modification of brake dust shields
5, Get a set of new brake line with correct length so it will fit the new caliper.

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For the brake system, you can either order a retrofit kit from BMW or order parts separately. The PN for the kit is 34112358378. The kit is a lot more cheaper than order all parts needed separately, even with a lot of of them from the kit won't fit on E60/E63 (servo, dust shield, brake sensor and some hardwares). You may able to put a system by ordering used parts to save money. If you want to order parts separately, here is a list that you will need:

34117850463 (front left caliper)
34117850464 (front right caliper)
34217850465 (rear left caliper)
34217850466 (rear right caliper)

34112284805 (front left rotor)
34112284806 (front right rotor)
34212284807 (rear left rotor)
34212284807 (rear right rotor)

34112284970 (front pads)
34212284990 (rear pads)

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The new brackets are coming from a company from Russia, Tim_1 found them first and used them. I contacted them and found out they have done this job before.


What I have done is to remove the rotor hat from the brake disc and sent them to this company, they modified the hat to fit for parking brake then send back to me, with the new brackets and stainless brake lines.

937638
 

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Discussion Starter #2 (Edited)
Here is a picture shows why we need new caliper bracket, note the mounting screw offset is different:

937639


New bracket to replace old one:

937640


Comparing E60 OEM brake and F80 CCB (this is the rear):

937643


We will use original front and rear dust shield but need to cut them in order to fit the new bracket. The rear dust shield is a bit small of its diameter and it barely fit the new rotor.

937641

937642
 

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Discussion Starter #3
The rear calipers have L and R mark on them, however the L is for the passenger side, dont be fooled by the mark on the caliper. This photo shows how tight the space between rear dust shield and the new rotor:

937644


Front looking good, but the dust shield is small for the big rotor

937645

937646



In the last, you need at least 19" wheel to fit this kit, I ordered BMW 763M which is stock for F80 M3 so I know it will fit. The space is very very tight on the front, I am not sure if other 19" wheel will work:

937647
 

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Discussion Starter #4
Additional notes:

1, I tried to fit the new brake servo but gave up eventually since it is not exact fit, they are actually quite different.
2, You will still use E60 brake sensors, one each on the front and only passenger side on the rear. The F80 brake sensor has different wire connector so it won't fit.
3, The retrofit kit comes with two dust shields (I believe they are for the front), they are no way to fit on E60 as well.
4, The brake line on the rear requires different length for E60 and E63. The lines coming from tronik barely long enough for my M6, Tim_1 said it is way too short for his M5 and need 30mm longer. Make sure you get the correct length for your car.

Final result:

937648


937649


937650


Will post some initial feedback of the performance later this weekend.
 

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they modified the hat to fit for parking brake then send back to me, with the adapters and stainless brake line
What mods had to be done to the rear hats? I assume the hats have a steel inner liner as a brake drum for the parking brake. Any pics of that?
 

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Discussion Starter #6
I forgot to take picture of that part since I can not remember what it was before the modification. From what I have seen, it appears they used CNC to cut some inner edge corner metal out, creating a chamfer, so the hat will not interfere with parking brake pad. This is a very minor change but has to be done. You need a CNC, milling machine or lathe to do it.
 

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I forgot to take picture of that part since I can not remember what it was before the modification. From what I have seen, it appears they used CNC to cut some inner edge corner metal out, creating a chamfer, so the hat will not interfere with parking brake pad. This is a very minor change but has to be done. You need a CNC, milling machine or lathe to do it.
yeah I have access to that stuff and i've done quite bit of machining and CNC programming on the side. What is the PN for the OE bracket? I'm interested in that. Also saw your M6 postings on weight savings, I hardly go over there. I've gutted a M5 so I can tell you pretty accurately what some stuff weighs. you can easy drop 200 lbs. and more.
 

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Discussion Starter #8
That will be easy, you can create the bracket for E60 by yourself. The OE bracket is a part of the caliper coming assembled together.

My initial feeling is the brake pedal no longer linear for what I can tell. The first 70% is a kind of spongy and the last 30% is strong, but not bite feeling. It does getting less spongy after warm up but not much different for now, I will put it on track and see what it will be.

As for the braking distance, it is definitely shorter as I can tell. However I still can not let ABS kick in with recently installed new set of Michelin P4S tires. The steering feels much more direct now which I like the most. Any no more brake dust:D
 

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yeah I was planning to make the bracket myself anyway if I ever do something like this but only if I do alot of track stuff. I'd prolly still stick with iron rotors and use the AP racing calipers I already have.

Maybe that is why I couldn't find the part of PN when looking in ETK are they the same left and right?

CCBs do need to be hot for them to be at their ideal frictional "mu". I've driven my friends C7 grand sport (with CCB 's at lauguna and thunderhill and they definitely bite.
 

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Discussion Starter #10 (Edited)
While doing research for a set of track wheel, I have found out BMW ccb's big caliper has limited my choice a lot. Most less than 20 lbs lightweight track use 19" wheels like TE37, G025, ZE40 and Avdan GT wont clear the caliper at all. If you like me, want 19" for weight saving then here are a few aftermarket 19" forged lightweight wheels that will fit:

HRE R101
BBS FI-R
BC Forged monoblock (indicate M3 F80 ccb when you place custom order)

Another issue is you will have about less than a finger's clearance between wheel and caliper so pebble will get into the gap and damage the wheel easily, this is a big probably on track since you always don't know when you may go wide and on gravel then you will be done. There is a discuss about this clearance issue and scratch seems to happen quite commonly:


Most 20" wheel will not have clearance issue at all and you can feel safe abusing them on the track. HRE R101LW 20" is still well above 20 lbs so it is the one of the best choice. However I am not really ready to throw $10,000 for a set of HRE for track use and be ready to trash them anytime. I will probably get a set of cheap 20" for track use. The Advan GT (about $4,000 per set) is my first choice. The 20x9 and 20x11 weight at 21 lbs and 22 lbs. That's an OK number and are about the same of my BMW 763M (19x9: 20.75 lbs, 19x10: 21.8lbs).

Tire choice depends on which wheel you want to go. You can go the following setup on 20" and it should not rubbing

265/35R20 front on 20x9
305/30R20 rear on 20x10.5 (or 20x11)

I am currently running following spec without any issue:

255/40R19 front on 19x9
295/35R19 rear on 19x10
with Michelin P4S

or maybe a bit bigger and still OK?

265/35R19 front on 19x9.5
305/30R19 rear on 19x10.5
with Michelin P4S or Cup 2

In both setup, you will need proper spacer to avoid rubbing.
 

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or maybe a bit bigger and still OK?

265/40R19 front on 19x9
305/35R19 rear on 19x10
with Michelin P4S or Cup 2

In both setup, you will need proper spacer to avoid rubbing.
On my e60, I'm running 275/35/19 and 305/30/19 AD08R. I ran the same size PS4Ss on 19lbs DINAN LTW 19x9 ET18, 19x10 ET25, with a 15mm spacer up front.

No rubbing, corner balanced, with MCS 2WNR. My brakes are StopTech 6/4 380mm/35mm x 380mm/32mm.

Overall, I dropped quite a bit of weight over OEM and only a couple pounds over your CCBs.
 

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Discussion Starter #12
On my e60, I'm running 275/35/19 and 305/30/19 AD08R. I ran the same size PS4Ss on 19lbs DINAN LTW 19x9 ET18, 19x10 ET25, with a 15mm spacer up front.

No rubbing, corner balanced, with MCS 2WNR. My brakes are StopTech 6/4 380mm/35mm x 380mm/32mm.

Overall, I dropped quite a bit of weight over OEM and only a couple pounds over your CCBs.
I will keep my eye on a set of used 19" BBS FI-R on M3 form. If I go this way then I will still 50 lbs lighter because of the CCB saving.
 
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