Carbon ceramic brake system installation on DODGE CHALLENGER SRT® HELLCAT, the beginning…

SRT is a magical symbol, a rampant force enwrapped in a tire smoke. Full car weight is over 2000 kg, and about 1000 HP.

Good day to you!
For starters a few numbers from technical car presentation:
2017 
DODGE CHALLENGER SRT® HELLCAT 
Supercharged 6.2L HEMI® SRT V8 Engine with 707 HP and 650 LB-FT of Torque 
Available Class-Exclusive TorqueFlite® Eight-Speed Automatic Transmission 

SRT is a magical symbol, a rampant force enwrapped in a tire smoke. Full car weight is over 2000 kg, and about 1000 HP.
Standard brake system: 
Front axle brake rotor 390-34 on a floaing bobbins, 6 pot Brembo caliper with “ears”.
Rear axle brake rotor 350-28 monolith, 4 pot Brembo caliper with “ears”.

The car came for measurements.
Decision was made to use Carbon-ceramic components.

Needed parts were designed.

We want to share with you a joyful event! 
Our company is expanding our machine park.
At the moment modern means of production joined our universal turning and milling machines!
1. Vertical machining center, initial level of size and equipment for Siemens 828D, 10000 RPM 

2. Turning lathe with 12 position revolver and, the most important, with a power tool, transporter, and other similar options, Numerical Control Siemens 828D и ShopTurn.
This particular project was was fully implemented on our equipment!

Front axle: 
— carbon-ceramic brake rotor 410-38 
— 6 pot Brembo caliper
— carbon-ceramic brake pads, additional facet was created.

Designed and made:  
— brake rotor hat (410-38) D16T material, protective galvanic layer  
— adapters, D16T material, protective galvanic layer  
— new size dust shields, standard has no shields at all!
— Goodridge brake lines
— painted calipers

Rear axle: 
— carbon-ceramic rake rotor 396-26 
— 4 pot Brembo caliper 
— carbon-ceramic brake pads

Designed and made:  
— brake rotor hat w/ parking brakes’ drum, D16T material, protective galvanic layer  
— adapters, D16T material, protective galvanic layer  
— new size dust shields
— Goodridge brake lines
— painted calipers
 
Billet for dust shields were made ahead (laser cut).

Notice that holes for mounting dust shields in a knuckle are missing. 
First hole is ready! 

After adjusting the shield we set our way to swaging machine to make profile groove to increase the structure rigidity.

Front knuckle is made of cast iron, that limits the choice of adapter material.
As experience shows, parts made of D16T are sure to live no longer than 2 years in tough conditions of Moscow winters.
That’s why it is advised to go through a routine inspection once a year, including parts of brake system!
Choice of adapter material is dictated by operation intensity (number of hours spent in aggressive environment), estimated operation time. 
It is known, that if you connect two types of metal w/ different electrochemical potential and set into electrolyte environment (alkaline composition (car wash), or winter chemicals salts) galvanic pair is created.
In D16T copper is present in composition, which leads to rapid oxidation and to loss of strength properties. 
There are few ways to protect parts from aggressive environments.  
1. protective galvanic layer.
2. after tightening the adapter mounting screws to the knuckle treat it with a composition like Movil. 
3. make adapter from steel 
In our case the car is operated with great care, so a decision was made to create front adapters out of D16T.
Having a 3D model of a part and our own workshop, the production time comes to one or two days, taking galvanic layer into consideration.