BMW Caliper modification problem Options

[tornik550]

Long story how this happened however I was going to "upgrade" my front calipers to BMW 320i calipers. I was having the caliper flange machined and (long story) the flange is now a little too thin. The specs call for the flange to be 0.587" +/-0.005" and mine measure 0.539". Other than the obvious- scrap them and start with a new set- do I have any options? Can I can get a perfectly measured, very thin spacer and put it between the strut and the flange?

Also, are 19mm master cylinders needed for 320i calipers?

[rick 918-S]

Use the stock 914 calipers. Rebuild them with new rubber lines and use good pads and you'll have great brakes. 19mm master will give you a high pedel because of the increase in fluid volume it moves when the pedel is depressed.

If you start adding a larger contact patch and more unsprung weight you may want to consider increasing the clamping force by changing to a 4 piston style caliper of using a larger caliper and vented rotor.

Hp has nothing to do with stopping the car. 100 mph with 85 hp is the same 100 mph with 300 hp. A flat 4 with two fat guys weighs as much as a V8 car. The force required to stop both cars is equal. The formula changes when you add larger and wider tires with heavier wheels. The rotational force adds resistance. This requires more clamping force.

Here's my 2002 setup. I made the lines with a tubing bender and a bubble flare kit.