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Discussion Starter · #1 · (Edited)
I saw several threads about this in Focus ST and Mazdaspeed 3 forums. And it was briefly mentioned here in a few threads. I was surprised to find that nobody here made a thread about it.

Long story short, When I upgraded the front brakes from 300mm to 320mm in my C70, I also upgraded the rear brakes from the stock 280mm to 302mm using 2006-2015 Mazda 5 caliper brackets and 2016-2019 Focus RS Mk.3 rear rotors.

This idea is not mine or new by any means. There are old posts (around 2015 and older) that said to use V70 rear rotors, but with those have a larger center bore and wheel stud diameter, and can cause some issues. Later somebody found out the 2016-2019 Mk.3 Focus RS 302mm rear rotors have the same center bore and bolt diameter as our cars, making them a exact match. Original caliper is retained, and it does not affect the parking brake function.

Since the factory brake caliper is retained, same thing goes for the brake pads.

For those curious about rotor dimensions. Here is the info:

Volvo P1 rear brake rotors:

130179


2006-2019 Mk.3 Ford Focus RS rear rotors:

130180


As you can see, diameter and weight are the only differences.

Now regarding the brake caliper brackets:

You may be asking "Why Mazda 5 brake caliper brackets??". Well, first and foremost, this wouldn't be called "Frankenbrake" without parts from a 3rd vehicle in the mix. And second, the Mazda 5 is based in the same platform and they share several parts with our cars. One of them is rear brake calipers. And for some reason Mazda equipped it with 302mm rear brake rotors. So they needed to move the caliper farther from the wheel center. Hence the exclusive caliper bracket.

2006-2015 Mazda 5 rear brake rotors:

130181


As you can see, the rotor is similar to ours. But, since Mazda doesn't use the same wheel lug pattern and center bore, the conversion would not work (Unless you swap to mazda hubs and wheels). This was the reason why the "first" version of frankenbrakes used 2008-2010 Volvo V70 rear rotors, despite having a different centerbore and wheel bolt diameter, the wheel bolt pattern is the correct (5 x 108mm). Then, the Mk.3 Focus RS came out with its rear rotors that are a perfect fit for this.


I picked up a set of brackets from my local junkyard for ~$17 each. They had some corrosion, because part of the zinc plating was gone. So, I painted them with VHT Caliper Paint in cast aluminum color, since the calipers are actually made of aluminum.

130191


The bolt threads match with the original caliper bracket, But if you are doing this on a C70, You want to keep the original bracket to hub bolts. Because they are 5mm longer (C70 has a spacer behind the wheel hub)

Here's the comparison between brackets:

130182


These brackets move the caliper 10mm farther from the wheel center. Giving a little bit more of "lever-arm effect" and thus, should achieve more stopping power with the same clamping force. The dust shield still covers the rotor, and there's no need to replace it with the Mazda 5 part since they are the same. and also you would have to remove the hub to do so.


For brake rotors, I bought a set of Power Stop AR85181EVC at ~$41 each.

The parking brake cable does not require any modification. And since I was there, also upgraded to stainless steel brake lines.

130193



130194


Unless you are close to the car and recognize the "rounded" Focus RS rotor hat, you won't be able to tell the difference.

130195



This upgrade is not something that severely alters the braking bias of the car and could cause you to lose control of the vehicle. But I've noticed the car "squats" on its back slightly more while braking than before.


To me this was a good upgrade, since C70's are the heaviest, and IIRC, they carry more weight in the back than any other P1 vehicles. The upgrade should be more noticeable in other P1 cars since they're lighter. And best part is this is can be done with "off the shelf" parts.


Part numbers are:

Caliper brackets:
Vehicle: 2006-2015 Mazda 5
P/N: C2Y6-26-28XA

130197



Brake rotor part numbers:
Vehicle: 2006-2019 Mk.3 Ford Focus RS

Standard smooth rotors:

Brand:Part Number:Description
Centric Parts120.61123Smooth Rotor
Duralast75051DLSmooth Rotor
MotorcraftBRRF283Smooth Rotor
NAPAUP 882085CRSmooth Rotor
PowerStopAR85181EVCSmooth Rotor
StopTech120.61123CRYSmooth Rotor / Cryo
Zimmermann250.1397.20Smooth Rotor

Performance Brake Rotors:

Brand:Part Number:Description:
EBC BrakesUSR 2031Slotted / Pair (Left & Right)
StopTech126.61123S-SETSlotted / Pair (Left & Right)
StopTech126.61123SLSlotted / Left
StopTech126.61123SRSlotted / Right
StopTech126.61123CSLCryo / Slotted / Left
StopTech126.61123CSRCryo / Slotted / Right
PowerStopAR85181XPRDrilled / Slotted / Zinc Plated / Pair (Left & Right)
StopTech127.61123LDrilled / Sloted / Left
StopTech127.61123RDrilled / Sloted / Right
StopTech127.61123CLCryo / Drilled / Slotted / Left
StopTech127.61123CRCryo / Drilled / Slotted / Right
 

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Great write up!

Gonna have to try this for the s40


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Discussion Starter · #3 ·
For those with 16" wheels I still have to confirm if this fits with those. Once I get the chance to test it with one of my S40 wheels (16" Caligo), I'll report back.
 

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It seems there's well over half an inch of room between the rear caliper and wheel with 16x7" OEM (7-spoke, Adaro?) wheels so +22mm of rotor diameter / +11mm of radius and moving the caliper accordingly should still fit nicely.

Nevertheless, this sounds like an interesting mod. The brakes are slightly more rear-biased than in most cars to start with. Not excessively at all, the car is just less prone to lock the fronts than most, so increasing the rotor diameter may bring them even closer to ideal balance.

Mazda 5:s are rare in junkyards around here so I might have to order new brackets, at €100+ each.
 

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Discussion Starter · #5 ·
It seems there's well over half an inch of room between the rear caliper and wheel with 16x7" OEM (7-spoke, Adaro?) wheels so +22mm of rotor diameter / +11mm of radius and moving the caliper accordingly should still fit nicely.
Yeah, In my S40 with Caligo wheels (6.5”x16”) it seems there is more than enough clearance and they should fit without problems, but I wanted to confirm before posting.

Nevertheless, this sounds like an interesting mod. The brakes are slightly more rear-biased than in most cars to start with. Not excessively at all, the car is just less prone to lock the fronts than most, so increasing the rotor diameter may bring them even closer to ideal balance.
That’s exactly what I thought when I was about to upgrade the fronts to 320mm from the stock 300mm. This way the Front/Rear size ratio stays almost the same as before.

Mazda 5:s are rare in junkyards around here so I might have to order new brackets, at €100+ each.
Daang! ~€200 for a set of brackets??

When i was looking up the part numbers, I came across the Focus RS bracket. It has some casting differences with the Mazda 5 bracket and I couldn’t find any info of the bracket to hub bolt spacing. But if you can get them for cheaper and confirm if they fit, it would be awesome.

Here are the part numbers:

BRBCR26 (2B582) -> unpainted

BRBCR35 (2B511) -> painted in blue





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That’s exactly what I thought when I was about to upgrade the fronts to 320mm from the stock 300mm. This way the Front/Rear size ratio stays almost the same as before.
Mine is AWD 6-speed so it has 320mm fronts from the factory. The rears are, obviously, 280mm, which is slightly odd as AWD (and RWD) can typically benefit from better rear brakes a bit more than FWD. The choice was probably made by beancounters as usual.

[Focus RS bracket]. But if you can get them for cheaper and confirm if they fit, it would be awesome.
Thanks, I'll look into that. Mk.2 Focus RS isn't a common sight at junkyards either and whenever you come across one, it almost certainly is already missing essential goodies like model-specific turbo + exhaust manifold, suspension and brakes. Then again, pricing policy for spares seems to be a bit more sensible than that of Volvo.
 

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Discussion Starter · #7 ·
Thanks, I'll look into that. Mk.2 Focus RS isn't a common sight at junkyards either and whenever you come across one, it almost certainly is already missing essential goodies like model-specific turbo + exhaust manifold, suspension and brakes. Then again, pricing policy for spares seems to be a bit more sensible than that of Volvo.
That bracket is from mk.3 Focus RS


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Thanks for the clarification.

And, by the way, are all Mazda 5 rear brackets compatible with P1? I think I've managed to find a couple of 2.0 diesels in junkyards now and if the brackets are the same, there's an opportunity to save some money.
 

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I saw several threads about this in Focus ST and Mazdaspeed 3 forums. And it was briefly mentioned here in a few threads. I was surprised to find that nobody here made a thread about it.

Long story short, When I upgraded the front brakes from 300mm to 320mm in my C70, I also upgraded the rear brakes from the stock 280mm to 302mm using 2006-2015 Mazda 5 caliper brackets and 2016-2019 Focus RS Mk.3 rear rotors.

This idea is not mine or new by any means. There are old posts (around 2015 and older) that said to use V70 rear rotors, but with those have a larger center bore and wheel stud diameter, and can cause some issues. Later somebody found out the 2016-2019 Mk.3 Focus RS 302mm rear rotors have the same center bore and bolt diameter as our cars, making them a exact match. Original caliper is retained, and it does not affect the parking brake function.

Since the factory brake caliper is retained, same thing goes for the brake pads.

For those curious about rotor dimensions. Here is the info:

Volvo P1 rear brake rotors:

View attachment 130179

2006-2019 Mk.3 Ford Focus RS rear rotors:

View attachment 130180

As you can see, diameter and weight are the only differences.

Now regarding the brake caliper brackets:

You may be asking "Why Mazda 5 brake caliper brackets??". Well, first and foremost, this wouldn't be called "Frankenbrake" without parts from a 3rd vehicle in the mix. And second, the Mazda 5 is based in the same platform and they share several parts with our cars. One of them is rear brake calipers. And for some reason Mazda equipped it with 302mm rear brake rotors. So they needed to move the caliper farther from the wheel center. Hence the exclusive caliper bracket.

2006-2015 Mazda 5 rear brake rotors:

View attachment 130181

As you can see, the rotor is similar to ours. But, since Mazda doesn't use the same wheel lug pattern and center bore, the conversion would not work (Unless you swap to mazda hubs and wheels). This was the reason why the "first" version of frankenbrakes used 2008-2010 Volvo V70 rear rotors, despite having a different centerbore and wheel bolt diameter, the wheel bolt pattern is the correct (5 x 108mm). Then, the Mk.3 Focus RS came out with its rear rotors that are a perfect fit for this.


I picked up a set of brackets from my local junkyard for ~$17 each. They had some corrosion, because part of the zinc plating was gone. So, I painted them with VHT Caliper Paint in cast aluminum color, since the calipers are actually made of aluminum.

View attachment 130191

The bolt threads match with the original caliper bracket, But if you are doing this on a C70, You want to keep the original bracket to hub bolts. Because they are 5mm longer (C70 has a spacer behind the wheel hub)

Here's the comparison between brackets:

View attachment 130182

These brackets move the caliper 10mm farther from the wheel center. Giving a little bit more of "lever-arm effect" and thus, should achieve more stopping power with the same clamping force. The dust shield still covers the rotor, and there's no need to replace it with the Mazda 5 part since they are the same. and also you would have to remove the hub to do so.


For brake rotors, I bought a set of Power Stop AR85181EVC at ~$41 each.

The parking brake cable does not require any modification. And since I was there, also upgraded to stainless steel brake lines.

View attachment 130193


View attachment 130194

Unless you are close to the car and recognize the "rounded" Focus RS rotor hat, you won't be able to tell the difference.

View attachment 130195


This upgrade is not something that severely alters the braking bias of the car and could cause you to lose control of the vehicle. But I've noticed the car "squats" on its back slightly more while braking than before.


To me this was a good upgrade, since C70's are the heaviest, and IIRC, they carry more weight in the back than any other P1 vehicles. The upgrade should be more noticeable in other P1 cars since they're lighter. And best part is this is can be done with "off the shelf" parts.


Part numbers are:

Caliper brackets:
Vehicle: 2006-2015 Mazda 5
P/N: C2Y6-26-28XA

View attachment 130197


Brake rotors:

Car: 2006-2019 Mk.3 Ford Focus RS

Brand: P/N:

Zimmermann 250.1397.20
Motorcraft BRRF283
Duralast 75051DL
NAPA UP 882085CR
Centric Parts 120.61123
Power Stop AR85181EVC

(all of these are for standard solid rotors)
Just got off the phone with EBC. I’m sending back the USR Slotted “stock” discs for the rear and they (verified the above specs) and are sending me the 2016 Focus RS discs. I also bought two rear calipers with brackets, only way they sell them (2008 Mazda 5) at my local parts store and they are going to take the Mazda calipers back with my stock rear Volvo brackets for a core refund. Should have this “frankenbrake” set up for the rears and Wilwood 4 pots for the fronts with 320mm USR discs by the end of the weekend. Thanks for the write up and time spent sorting and compiling…
 
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Discussion Starter · #10 ·
are all Mazda 5 rear brackets compatible with P1? I think I've managed to find a couple of 2.0 diesels in junkyards now and if the brackets are the same, there's an opportunity to save some money.
No, it can be with 280mm rotors (same as Volvo P1) and 302mm rotors according to the ATE web catalog (Links here and here). This applies to the CR19(2005/6-2010 and CW (2010-2018?) generations of Mazda 5.

Go to take a look if you can. It's a 50/50 chance those brackets are the ones you are looking for.
 

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Discussion Starter · #11 ·
Just got off the phone with EBC. I’m sending back the USR Slotted “stock” discs for the rear and they (verified the above specs) and are sending me the 2016 Focus RS discs. I also bought two rear calipers with brackets, only way they sell them (2008 Mazda 5) at my local parts store and they are going to take the Mazda calipers back with my stock rear Volvo brackets for a core refund. Should have this “frankenbrake” set up for the rears and Wilwood 4 pots for the fronts with 320mm USR discs by the end of the weekend. Thanks for the write up and time spent sorting and compiling…
You're welcome! And don't forget to share part numbers and pictures of the new setup.
 

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Maybe someone can confirm, but it looks like StopTech Rotors would be:

126.61123S-SET
126.61123SR
126.61123SL
…for slotted.

Cryo Slotted are 126.61123CS
(or perhaps not as photos accompanying this are vented)

Maybe 126.61123 for un-slotted?
 
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Maybe someone can confirm, but it looks like StopTech Rotors would be:

126.61123S-SET
126.61123SR
126.61123SL
…for slotted.

Cryo Slotted are 126.61123CS
(or perhaps not as photos accompanying this are vented)

Maybe 126.61123 for un-slotted?
Rears are coming along, literally just got the Wilwood 4pots in hand for the front….
130665



130666

130668
 

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Discussion Starter · #15 ·
Maybe someone can confirm, but it looks like StopTech Rotors would be:

126.61123S-SET
126.61123SR
126.61123SL
…for slotted.

Cryo Slotted are 126.61123CS
(or perhaps not as photos accompanying this are vented)

Maybe 126.61123 for un-slotted?
According to summit racing, parts numbers are correct, except 126.61123CS. I can't find this P/N as a set.

I'll add them to the list.
 

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Discussion Starter · #16 · (Edited)
Confirmed: Frankenbrakes will fit in 16” Caligo wheels.



There is a ~6 mm gap between the caliper and wheel.



And will also fit in the 16” spare wheel. With less gap (~5 mm) than the Caligos.




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Confirmed: Frankenbrakes will fit in 16” Caligo wheels.



There is a ~6 mm gap between the caliper and wheel.



And will also fit in the 16” spare wheel. With less gap (~5 mm) than the Caligos.




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22 miles on new upgrade, thanks Facusan!
Confirmed: Frankenbrakes will fit in 16” Caligo wheels.



There is a ~6 mm gap between the caliper and wheel.



And will also fit in the 16” spare wheel. With less gap (~5 mm) than the Caligos.




Sent from my iPhone using Tapatalk
Just put the first 22 miles on the new set up. After bed in (500miles) will report back, gotta say, huuuuuuge difference and highly recommended to anyone looking to upgrade their brakes. Just do it. (Don’t tell Nike) Shhhhhhh. Thanks Facusan!
131039

131040
 
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