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Astra G and Zafira Turbo Brakes

We have a range of uprated brake discs, pads and brake upgrade kits for Astra G, from Fast Road Pads to our 322mm Brake Upgrade Kit, the 4 Pot AP/VXR, 6 Pot D2 and 8 Pot KS kits offering huge stopping ability. More Details of all our brakes, including discs for other models can be found on our Brakes Page

Courtenay 16G Front and 8G Rear Brake Discs

Courtenay 16 Groove 308mm brake discs for greater stopping ability due to increased surface area. The grooves also help to keep the pads clean and disperse heat, brake dust and gasses away from the disc surface, a common cause of brake fade. Suitable for Astra and Zafira turbo models

Front 16G Discs 308mm - £195 pair Buy Now Click Here!

Rear 8G Discs - £148.95 pair Buy Now Click Here!
308mm Courtenay 16 Grooved Front Disc
Full Size Image - Shows 322mm disc Upgrade - Click Here
16G disc shown fitted.

EBC Uprated GD Sport Discs

As an alternative to our 16G and 8G discs, we also offer the EBC Turbo Grooved and dimpled discs. EBC's wide groove discs are designed to pull cool air under the pad surface and between the disc to help both pad and disc cooling. EBC's "Blind Drilled" dimples help break down surface gasses but do not promote cracking, which has been known to occur, especially on fast road and track day use with conventional "Through Drilled" discs.

As well as aiding cooling, the grooves in the disc surface also allow dirt, dust, gasses, debris and grit to escape from between the disc and pad surface, especially under heavy braking. The grooves and dimples also keep the pad surface de-glazed throughout its useful life.

EBC sport discs are also coated to help prevent from corrosion in areas which are not swept by the pad to help them stay looking better for longer. Optimum brake performance is reached once the coating is removed from the pad contact area, which when used with EBC ceramic pads and the special brake in coating on their surface  will often occur in as little as 50 miles.

As with our own 16G discs it is normal to expect a little additional brake noise from these discs during normal use.

Excellent as a fast road disc. Ideal for use with red and yellow ceramic pads.

Front EBC Discs 308mm - £171.00 pair  Rear EBC Discs - £102.10 pair

Uprated Brake EBC Pads

For use with our 16G discs and EBC discs, we supply Red Ceramic pads for fast road use, ideal as a good alternative to the OE pad working at up to 550 degrees C or Yellow ceramic pads which work at higher temperatures than the Red pads for more spirited driving on road driving and light track work (e.g. trackdays). Available for Front and Rear.

Red Pads -  Yellow Pads -

Brembo Sport Brake Pads

Brembo Logo
Designed for the road, developed on the track.

The new sport pad range is the latest pedigree to come out of the Brembo high performance stable. Tested to the highest levels on the track with decelerations from 270 kph (168mph) the HP2000 material is capable of operating in the most demanding conditions.

With excellent cold performance & bite, high resistance to fade, frictional stability throughout all operating conditions, reduced pad & disc wear and low dust levels, the all new HP2000 friction material offers significant advantages over its rivals. Designed to be a direct replacement for the Original Equipment (OE) pads the Brembo sport pad comes with the exact same specification as the OE pad including (where applicable): fitted wear leads, slots for separate wear leads and anti-rattle clips with the added benefit of anti-noise shims on every pad.

Combine all of this with competitive pricing and UNECE R90 approval across the full range (making them street legal) and you get a true high performance brake pad fit for the road.
Brembo Sport Pads Designed and tested for predominantly performance-oriented street use, Brembo Sport brake pads represent the first upgrade level for any braking system.

Designed and tested for predominantly performance-oriented street use, Brembo Sport brake pads represent the first upgrade level for any braking system. These products have been created for drivers with sporty ambitions and, more generally, for anyone who wants to maximise the potential of their car.
These pads boast levels of manufacturing quality and advanced materials that only Brembo can offer. They offer outstanding performance even without warming up and at low speeds, thanks to a specific friction material that ensures constant friction at all temperature ranges. In addition to enhanced performance, this material also ensures outstanding quietness and reduced disc and pad wear.
Excellent performance in all situations.

Brembo Sport brake pads also offer exceptional brake pedal precision, for total control of the braking force. While they work best at temperatures between 200 and 300 °C, they can withstand much higher temperatures - up to 600 °C - and are designed to deliver both superlative performance and satisfactory levels of comfort. These are therefore the ideal brake pads for drivers who demand the best from their brakes, even during everyday use.
Brembo Sport Pads
Available for Astra G with 308mm, 322mm VXR Discs and AP VXRacing 343mm Discs. Buy Now Click Here!

Front Pad Set from £124.80 :: :: Rear Pad Set £88.80

322mm Front Brake Upgrade


322mm Brakes

This 322mm Brake upgrade kit is suitable for 5 Stud Astra G and Zafira A, and will sit neatly under 17" alloy wheels. This upgrade kit includes a pair of 322mm vented discs, pads, callipers and brackets finished in VXR blue and VXR brake hoses.
322mm Brake Kit: Our Price £571.95 inc VAT 
Vauxhall Price £865
16 Groove Discs for improved stopping £76.95 extra

Red and Yellow Ceramic Pad upgrades available.


Under 17" Wheel

278mm Rear Brake Upgrade - Astra and Zafira

Our 278mm rear brake upgrade kit includes a pair of rear caliper backplate/mounting brackets, a pair of 278mm rear discs, a pair of rear VXR calipers (in blue), a pair of caliper mounting brakets (in blue) and a set of OE rear pads. We recommend that this upgrade is carried out only where the front brakes have already been upgraded to a minimum of 322mm, to prevent over braking the rear.

Vauxhall Retail Price £808.35 Our Price - £668.95 inc VAT

8 Groove Discs £76.95 extra. Red and Yellow ceramic pad upgrades available. Image shows OE Lucas pad set

Note: Calipers not shown in image.
 

292mm Rear Brake Disc Upgrade

In response to some serious fast road and track day warriors, we teamed up with our friend Dave Peace to develop an Astra H VXR 292mm Vented rear brake kit to compliment the large front brake kits already on the market.

With large front brakes the car nose dives and tries to grind the front splitter into the tarmac, whilst the rear of the car can become very light. The larger diameter rear discs even this out making the car flatter under braking.

For those people who track their car hard, the vented rear discs will be a big bonus as the factory ESP system works the rear brakes very hard during hard & high speed cornering, as the ESP remains partially active even when switched off via the sport button.

This kit has been developed and tested on both Dave’s and our own cars and is fitted to our own Astra Sprint, and has been tested on track and at the legendary Nürburgring Nordschleife. We have also got a kit running on an Astra VXR/OPC Race car in South Africa where overheating was a big issue!!

Here is what is included:

2 x 292mm Vented Rear Discs
2 x Caliper Carriers
2 x Caliper Bodies
2 x Billet CNC Machined Backplates/Caliper Mounting Brackets
1 x OE Pad Set
2 x Anti Rattle Springs
4 x Caliper Mounting Bolts
4 x Stainless Steel Braided Hoses

Whilst this kit has been designed for Astra VXR, it will fit Astra G and H and Zafira A and B, providing suitable front brake upgrades have been carried out.

Kit Price - £795.00 with plain discs. 8 Groove Discs - £76.95 extra with kit.

Replacement Discs :: 8G Brembo Discs £180.00 Plain Discs £99.00


292mm Brake Kit

Fitted - Plain Disc

Fitted - 8G Disc

Braided Brake Hoses - Front and Rear


Brake Line Kit - Astra G
 Courtenay Sport Braided Brake Hose Kits. Stainless steel braided hoses, plastic coated to resist dirt, rain, salt and fitted with high quality stainless steel unions. Improves pedal feel, eliminates ballooning caused by rubber OE hoses, improves braking performance. Stainless unions are more resistant to corrosion - some similar kits use zinc coated unions which are not as hard wearing and more prone to corrosion. Braided Brake Hoses are available for front standard (OE) calipers, cars  running 322mm VXR brake upgrades and for the rear brake hoses.
Front £45.00 per pair  Rear £69.00 per set of four

K Sport 8 Pot 330 & 356mm Brake Kit - Astra G, Zafira A

K Sport 356mm 8 Pot Brake Kit This kit comprises of a pair of 2 piece 330mm or 356mm x 32mm 8 grooved discs with alloy bells, Lighweight Alloy K Sport 8 pot calipers, brackets and stainless steel braided front brake hoses. The calipers are machined from aircraft quality billet with machined grooves to protect the bridge link pipes and have alluminium pistons, high temp seals and stainless steel brake pad wear plates.

The calipers are finished in Black. Pads can be specified to suit requirements.
Red Ceramic pads make a good fast road pad, Yellow Ceramic pads make good fast road and track day pads, whilst Blue ceramic pads are available for track/race use. Other pad compounds including Pagid RS29 and Ferodo DS2500 are available.

The lightweight caliper come in differential bore configuration. They are machined from aircraft quality billet and weigh just over 3kgs each, and have protection grooves machined in for the bridge tubes. Aluminum pistons, high temperature seals, and stainless steel brake pad wear plates are also standard on each caliper. The opposed piston caliper design greatly improves pad wear and caliper rigidity over the OE design. The stainless steel brake lines stop expansion under pressure.

The kit uses the 2-piece disc assembly which reduces weight both rotating and unsprung. The floating disc also stops thermal stresses of extreme heat from warping the disc or cupping the braking surface. The unique slot design on the rotor greatly reduces braking noise and expels gas and pad debris faster than conventional slot designs. Every rotor is always heat treated and balanced before shipment for the best possible performance.

This brake kit will fit under 18" Team Dynamics Pro Race 1.2 Wheels ET35mm and ET40mm, and other wheels including standard 18" Asta VXR Snowflake Wheels and the optional 19" Astra VXR Wheel (clearance is close on the 19" wheel and a 3mm - 5mm spacer is suggested). If in doubt please ask.

356mm Kit Price £1099.00 Buy Now Click Here! :: Requires 18" wheels with correct offset for clearance.
330mm Kit Price £999.00 :: Requires 17" wheels with correct offset for clearance.
Fitting available in our workshop.

Replacement Pad Sets available from £115.20. Available Pad Compounds include: EBC Yellow and Blue NDX, Pagid RS29, Ferodo DS2500 and Performance Friction. Buy Now Click Here!

Replacement Discs 330/356mm £359.00 per pair Buy Now Click Here!

D2 6 Pot 330mm and 356mm Brake Kit

D2 356mm 6 Pot Brake Kit D2 Racing big brake kits are designed to cope with the heat generated by extreme braking on the road or track. Where as the standard braking system will quickly overheat and no longer perform the D2 Racing brake kits will dissipate this heat so keeping the braking system within its operating parameters allowing you, the driver, to brake for much longer and much harder.

This kit comprises of a pair of 2 piece cross drilled discs with lightweight aluminium bells, lightweight strong aluminium 6 pot calipers, steel mounting brackets, stainless steel braided front brake hoses, fast road brake pads and 1L DOT5.1 Brake Fluid.

The calipers are CNC machined from aluminium with lightweight aluminium pistons and external dust seals. They have strong thick aluminium bridge supports that double up as pad retainers helping increase the rigidity of the calipers to prevent flex and maximise pedal feel and use one of the most popular pads shapes offering an excellent choice of pads.

The mounting brackets are cast from S45C steel and then CNC machined for strength and accuracy of fit.
The calipers are finished in painted Red; painted Black, Purple or Yellow are available at no extra cost. Other colour finishes are available at extra cost to special order.

The supplied pads are of a fast road/mild track day material specification but other pads can be specified to suit requirements at a small surcharge, depending upon the chosen pad. Optional pads include EBC Red, Yellow and Blue Ceramic, Ferodo DS2500, Pagid RS29

The disc sizes are 330mm or 356mm x 32mm.

Red Ceramic pads make a good fast road pad, Yellow Ceramic pads make good fast road and mild track day pads, whilst Blue ceramic pads are available for track/race use. Other pad compounds including Pagid RS29 and Ferodo DS2500 are available.

The 356mm kit will fit under 18" Team Dynamics Pro Race 1.2 Wheels ET35mm and ET40mm, Standard 18" Snowflake Wheels and the optional 19" Astra VXR Wheel (clearance is close on the 19" wheel and a 3mm - 5mm spacer is suggested which we can supply if required).

356mm 6 Pot Kit £1325.00 ::Fitting available in our workshop. Requires 18" wheels with suitable offset.

330mm 6 Pot Kit £1249.00

Replacement Pad Sets available from £122.50. Available Pad Compounds include: EBC Yellow and Blue NDX, Pagid RS29, Ferodo DS2500 and Performance Friction.

Replacement Discs 330/356mm £359.00 per pair
D2 6 Pot Caliper D2 Brake Disc and Bell Assembly D2 6 356mm Pot Brake Kit D2 Caliper Seals D2 Caliper Bridge

VXRacing AP 4 Pot Kit

This Brake Kit comprises of a pair of 2 piece 345mm 6 grooved discs with alloy bells, AP Racing 4 pot callipers with road seals, braided front brake hoses, brake pads and AP brake fluid.
The callipers are available in either Red or Blue with the both the VXRacing and AP Racing logos.
Blue Kit £2074.50 Red Kit - Enquire :: Fitting available in our workshop. Requires 18" wheels.

Available Pad Compounds: Mintex M1144, Brembo HP2000 Sport, Pagid RS29, Original Spec Pads. Buy Now Click Here!
Replacement Brake Discs £558 per pair Fitting kits available.

292mm Astra VXR Rear Brake Upgrade

In response to some serious fast road and track day warriors, we teamed up with our friend Dave Peace to develop an Astra VXR 292mm Vented rear brake kit to compliment the large front brake kits already on the market.

With large front brakes the car nose dives and tries to grind the front splitter into the tarmac, whilst the rear of the car can become very light. The larger diameter rear discs even this out making the car flatter under braking.

For those people who track their car hard, the vented rear discs will be a big bonus as the factory ESP system works the rear brakes very hard during hard & high speed cornering, as the ESP remains partially active even when switched off via the sport button.

This kit has been developed and tested on both Dave’s and our own cars and is fitted to our own Astra Sprint, and has been tested on track and at the legendary Nürburgring Nordschleife. We have also got a kit running on an Astra VXR/OPC Race car in South Africa where overheating was a big issue!!

Here’s what you get.....

2 x 292mm Vented Rear Discs
2 x Calliper Carriers
2 x Calliper Bodies
2 x Billet CNC Machined Calliper Brackets
1 x Pad Set
2 x Anti Rattle Springs
4 x Caliper Mounting Bolts
4 x Stainless Steel Braided Hoses

Whilst this kit has been designed for Astra VXR, it will fit Astra G and H and Zafira A and B, providing suitable (i.e. 4 pot) front brake upgrades have been carried out.

Price - £765.00 8G Discs - £76.95 extra with kit.

Replacement Discs :: 8G Brembo Discs £180.00 Plain Discs £99.00

Racing Brake Fluid

Delphi Lockheed Racing Brake Fluid has been formulated for racing applications where braking systems operate at high temperatures. It guards against vapour lock and maintains its viscosity and lubricity at extreme temperatures. This fluid conforms to and exceeds the current specification for DOT4 and has a typical dry boiling point of 310 o C (590 o F), which is higher than DOT5.1 fluids which typically have a dry boiling point of 260 o C.

£12.60 per 500ml. Buy Now Click Here!

DOT 5.1 Brake Fluid

DOT 5.1 Brake Fluid, ideal for fast road use as it has a typical dry boiling point of in excess of 260 o C,  which is higher than DOT4 fluids which are usually supplied from the factory.

£12.60 per litre. Buy Now Click Here!

Brake Fluid - Some Facts

Due to the fact that a brake system is not perfectly sealed moisture can be absorbed by the fluid. This in effect reduces the boiling point of the fluid and can reduce the efficiency of the brake system. Another factor of reduced braking efficiency is fluid that has got too hot and boiled, turning it into gas which leads to a 'spongy' feeling.

Brake fluids are classified to defined specifications: DOT3, DOT4, DOT5, DOT 5.1 These sepcifications have two reference tests:
Dry Boiling Point, the boiling point of fresh fluid
Wet Boiling Point, the boiling point once the fluid has absorbed water, representing fluid that has been in use in a vehicle.

There are two main types of brake fluid:
DOT3, DOT4, DOT 5.1 which are glycol based (Poly Alkylene Glycol - PAG)
DOT 5 which is synthetic based.

The two types of fluid are not compatible and must not be mixed in a braking system.
Minimum Dry and Wet Boiling point specifications:
Minimum Boiling Point oC DOT 3 (PAG) DOT 4 (PAG) DOT 5 (silicone) DOT 5.1 (PAG) Racing Brake Fluids
Dry 205 oC 230 oC 260 oC 260 oC 300 oC
Wet 140 oC 155 oC 185 oC 185 oC 195 oC
Slicone Brake Fluid (DOT5)
DOT5 was introduced to give higher temperature performance over DOT4. It will also not damage paintwork or absord moisture. However it is a poor lubricant and does not lubricate ABS pumps as well as PAG fluids and as it does not absorb water, any water in the system will remain as water droplets which can pool and cause corrosion or vaporise when heated under heavy braking causing severe braking efficiency loss.

PAG Brake Fluids (DOT3, 4 & 5.1)
DOT4 is the current mainstream brake fluid. DOT 5.1 has a higher specification and is intended for fast road and occasional track day use.
Racing brake fluid is usually designated DOT4 however it's performance exceeds that of DOT 5.1 fluid as shown in the above table.

© Copyright Courtenay Sport Ltd


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Courtenay Sport Vauxhall Tuning
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 Vauxhall Tuning

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