X-Line PB62I Big Brake Kits



Our PB62I big brake kits include:

  • 2 x PB62I compact billet 6-piston race calipers featuring stainless steel pistons and hardware (hard anodized).
  • 2 x 2-Piece floating disc assemblies featuring our SASS-float system, staggered cooling vanes and billet hats (hard anodized).
  • 2 x Billet aluminum caliper mounting brackets (hard anodized).
  • 2 x Stainless steel braided Teflon brake lines with 32-strand stainless steel braid and stainless steel end fittings.
  • All necessary mounting hardware.
  • Comprehensive installation and bed-in instructions.

Our X-Line PB62I big brake kits are extreme-duty kits intended for mid-heavy weight race / track day cars, off-road race cars and powerful street cars - especially those running 16 or 17" wheels. The 6-piston calipers are designed around a 20mm thick pad profile that offers in increased pad volume and results in excellent pad wear life. The pad profile is commonly available from all major pad manufacturers in a wide variety of compounds. Our PB62E caliper accepts disc diameters of 315-330mm with a disc thickness of 32mm. The discs and calipers used in our PB62I big brake kits were originally developed for works off-road race cars taking part in the gruelling Dakar Rally (over 5600 miles of racing in 12 consecutive days over extreme terrain). While a typical Dakar race car weighs 5500 pounds at the start of a stage, the cars often run 16" wheels. This limits the size of the brake discs and calipers considerably, posing a real challenge to the brake system suppliers. The design brief when we developed our PB62I 6-piston big brake kits was to engineer the maximum performance and durability into a very compact package. The result was a resounding success with our PB62I kits now being used by about half of the top-20 finishers at the Dakar with many stage wins and podium finishes by works teams. We then started getting calls to develop a wider range of PB62I big brake kits for a wide variety of track applications in cases where customers wanted to fit the absolute maximum brake package under 16 or 17" wheels. In response to this we have developed a range of street, track day and circuit race kits for popular production car platforms such as the Ford Focus ST, Mazdaspeed 3, Subaru WRX, VW Golf GTi - as well as bespoke kits for vintage race applications where wheel diameters are often small. Due to the excellent durability of the components in these kits, our PB62I kits have also become a popular choice for 2, 3 and 6-hour endurance races.

The features found in our PB62I big brake kits perfectly reflect our X-Line design philosophy of:

EXCEPTIONAL PERFORMANCE - EXTREME DURABILITY - UNMATCHED VALUE.


Calipers:

Our PB62I caliper uses a 20mm thick pad profile that offers excellent pad life. The pad profile is available in just about every race pad compound on the world market, meaning that pad compound choice is practically limitless. The design of our PB62I caliper results in a very rigid, extremely compact 6-piston race caliper featuring differential piston bores to counter the tapered pad wear issues often associated with many ‘long’ race pad profiles. The caliper features internal fluid crossovers and protected bleed screws making it suitable for both road and off-road conditions. This is currently one of the leading calipers in use in FIA off-road racing world-wide. Also used in a number of street and road race applications. Other features include heavy-duty stainless steel pad abutments and mil-spec type-3 hard anodizing.

As with all Powerbrake X-Line calipers, the PB62I underwent extensive FEA analysis during its design. The caliper is machined from the highest quality aerospace grade aluminum billet using state of the art 5-axis CNC machinery.The calipers feature a type-3 mil-spec hard anodized finish for maximum wear resistance. The finish is impervious to heat damage even at extreme track temperatures. Calipers logo's and serial numbers are laser engraved resulting in marking that will never be damaged by brake fluid, solvents or heat. All calipers feature Powerbrake's Max Temp Recording (MTR) system that provides a permanent record of the maximum operating temperature reach by the caliper.

Our PB62I calipers are fitted with ultra-high temperature pressure seals, manufactured from a proprietary polymer, that have been tested to caliper temps in excess of 480 deg F without failure. The calipers feature internal wiper seals that protect the critical pressure seals from abrasion / damage and extend caliper service intervals. The internal wiper seal design allows for long term street use, while not being susceptible to melting under track conditions as is the case with the external rubber boots used by many of our competitors. As with all of our calipers, piston retraction is minimized, resulting in the shortest possible pedal travel under braking.

Extensive use of stainless steel components in all Powerbrake X-Line Calipers means that few, if any, competitive products will offer similar levels of corrosion resistance. All bleed screws, tube nuts, abutments plates, pad retention pins, anti-vibration springs and pistons in our X-line calipers are machined from stainless steel. This costs a lot more than the plated steel components that our competitors use but follows our design philosophy of Maximum Performance / Maximum Durability. The only hardware components used in our X-Line caliper that are not manufactured from stainless steel are the high-tensile caliper cross-bolts. These bolts are coated with a proprietary black coating that provides unmatched corrosion resistance (up to 1000 hours salt spray ISO 9227), chemical resistance and exceptional durability, while not negatively affecting bolt strength or service life at all. Again this level of investment on our part shows our dedication to building the most durable brake components on the market.

All Powerbrake X-Line calipers feature heavy-duty stainless steel pistons. The pistons are scalloped to allow super-heated air to escape from the piston cavity. The outside surfaces of the pistons (which come into contact with the caliper seals) are then polished to a mirror finish. This significantly extends caliper seal life. While considerably more expensive to manufacture than the aluminum pistons used by many of our competitors, stainless steel pistons conduct heat far slower than aluminum pistons. The result of this lower thermal conductivity is reduced chance of vapor lock caused by brake fluid boiling.


Discs:

The 2-piece, floating disc assemblies included in our PB62I big brake kits include rotor friction rings cast from a proprietary High Carbon cast iron with high level alloying elements that increase rotor durability under high temperature use. The friction rings are attached to lightweight billet aluminum hats that are hard anodized for maximum durability and laser engraved with Powerbake logo's and serial numbers for full traceability. The disc drive hardware includes twelve high-tensile drive bobbins and our proprietary SASS-float system. The SASS-float system (originally developed for works Dakar Rally teams) allows for all the benefits of a full-floating disc assembly, while practically eliminating any chance of caliper piston knock-back (often experienced under track day or race conditions). Another positive spin-off is that this system also ensures perfectly quiet operation when our X-Line big brake kits are used in street applications.

Our SASS-float 2-piece disc assemblies allow for both radial expansion and contraction (experienced during disc heating and cooling cycles) as well as 0.35mm of axial float as preferred in track / race applications. Our SASS-float system is another example of how our X-Line big brake kits deliver championship winning race technology that can also be used by street and track day enthusiasts with no negatives. The fact that our full floating disc assemblies allow the disc friction rings to expand and contract independently from the lightweight aluminum disc hats, substantially reduces stresses within the disc that would otherwise be caused by disc expansion at high operating temperatures. The design results in improved pedal consistency as well as reduced disc distortion and cracking.

The disc friction rings feature our staggered cooling vane design, which results in improved cooling vane surface area allowing the rotors to cool more efficiently. The discs undergo multiple stress-relieving processes during manufacture resulting in an extremely stable finished product that will outlast many competitive discs on the market. It takes 12 weeks to manufacture a batch of our discs from casting to finished product. All Powerbrake X-Line discs are chemically de-greased and coated with a proprietary dry coating that ensures quick bed-in and maximum friction levels. All Powerbrake discs feature our MTR (Max Temperature Recording) tabs for accurate recording of max disc temps (4 - levels).

Every single Powerbrake disc assembly is measured in all key dimensions using measuring equipment capable of measuring accurately to tolerances of 10 micron. When it comes to QC, there is no batch or statistical quality checking of Powerbrake discs. Every single disc is measured. Our machining tolerances are up to three times tighter than the industry norm.

Caliper mounting brackets:

The caliper mounting brackets supplied in Powerbrake X-Line big brake kits are machined from aerospace grade billet aluminum. The resulting brackets offer an excellent balance between very high strength and ultra light weight. Our caliper mounting brackets are all type-3, mil-spec hard anodized. Each bracket is laser engraved with the Powerbrake logo, serial numers and other key information for easy identification and traceability.

Brake balance:

As with all our X-Line big brake kits, each PB62E kit is tailored to the target vehicle in question. This involves careful software modelling of correct brake balance, brake torque outputs and pedal feel using proprietary brake simulation software developed in-house by Powerbrake. The result is that the caliper piston diameters in each kit are specified to match the target vehicle in question. Brake balance is optimized to best suite each vehicle platform and will perfectly integrate with ABS, EBD and other vehicle stability control systems. When driving a car fitted with a Powerbrake X-Line big brake kit, you will feel this attention to detail coming through by the way that the vehicle chassis reacts under braking. Powerbrake engineers have developed our brake simulation software over many years. This software is a key element in the success of our X-Line big brake kits.