Everyone who owns a mk1 Fiesta eventually realizes that the front brakes suck. They are too small, the rotors warp easily, and they are thin and unvented. If you can actually find them, the logical thing to do is to source a set of big brakes off a Mk1 XR2 from BAT or the UK. They are engineered to take the beating of a go-fast Fiesta, and they bolt right up if you have larger wheels. But here's the rub, the hanger brackets for the front calipers are as rare as hen's teeth. Parts suppliers in the UK don't have them, and I dont see them on eBay very often.So what to do? Well, you could get a kit from Wilwood or Hi-spec from the UK via Burton power, £400-£500, have them shipped, £200, then buy some 15" wheels and tires, $800-$1000 plus shipping, $200...so for $2200 $2500 US, you can make the fiesta stop on a dime.
There is a slightly cheaper option in the states, Kustom Engineering has a kit also for 15" wheels, I think $699 plus shipping, plus wheel costs. So sub $2000.
...or you can do this.
1.) Buy a set of rotors for a 2000 ford focus from your local auto parts store. I paid $26 each.
2.) Buy or source a set of calipers with mounting hardware and brake pads and all the hardware for a 1987 BMW 325is. I found fully loaded calipers(calipers, brackets, pads, hardware) at Rockauto on closeout for $27 a corner. Shipping was only $11.
3.) Find a machine shop and have them mill the brackets so that they center on the rotors when mounted to the Stock Fiesta Hub. I have a guy that will do this for me, and will post cost and amount of the bracket he takes off so you know what to tell your machinist. My guess is the labor will cost me $50-$75.
4.) I haven't mounted these yet, but I think my stock lines will work, if not I'll get some braided stainless lines.
I found this buried in the archives of the US Fiesta enthusiasts group on yahoo groups. If you do own a fiesta, you really should join that group. It's such a helpful resource.
Ok so the parts were $106, plus 11 shipping and I already have 14" wheels, and I will need to pay to have the parts machined. So maybe it will cost $200 all-in. Still, pretty cheap for these massive, readily available parts.
Also, if you try this and they fail, you do it at your own risk and assume all liability. I am not an engineer, and make no claims that this is safe.
