I'd recommend sticking with the 10.1" brakes, they are more than enough especially with good pads. I'm running the dual piston Girling 60s on my Mk1, and they really need a bigger MC too if you haven't upgraded to the later 22mm. I have rear discs as well, and I ended up using the Audi 25.4mm MC because my brakes didn't engage until about 2/3 travel. Also the Girling 60s weigh a lot more, and you do feel that unsprung weight going over rough patches in a Mk1. Lastly, it's a pain to find wheels under 16" that fit with the calipers. I had to grind the calipers and run spacers.
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I did the Brembo 18Z(Touareg/Cayenne/Q7 calipers) on mine. It wound up being relatively cheap, less than $1000, but I used normal powerslot slotted rotors not 2 piece fancy rotors. They were relatively cheap and look awesome. Wheel clearance is a MAJOR issue, finding wheels to clear with anywhere near stock offset is very hard. They do NOT have bias issues that some people complain about when putting them on other MKV and MKVI cars, I would say my car brakes in a very balanced way.
Fresh rebuilt these where striped completely down glass beaded and then painted they need some touch up from being moved arpund but still look good haven't seen any brake fluid since the rebuild.
I'd go with Porsche calipers on stock rotors, which is what I run. MUCH improved pedal feel and modulation, ability to swap pads without taking the caliper off, and more pad options.
I've got an Audi A4 Quattro that I DD, Autocross and teach HPDE ( Track Days ). Originally I tried the TT carrier / A8 rotor (312mm ) upgrade. I later switched to Porsche Boxster calipers because I was getting pad taper on Track Days.
It's a known problem with knocking brakes on the off rear of B6 passats. To fix, remove the caliper, pull out the top and bottom did pins and half fill with a heavy grease or copper grease into the holes the slide pins slide on, refit and no more noise! Just did mine last week.
I agree that girling 60 are too heavy compared to 54. With good pads 54 offer more than enough stopping power.
Brakes: 11" Rotors with Wilwood Dynalite Calipers, stainless lines and Hawk pads.
ok so those are the front calipers on my mk1 golf.. (83 golf GL... german market) they are ATE brand and are stamped VWII looking at the rotors and pads it seems something funky is going on. the contact area on the rotor seems tiny.. and the pads hang off of it (the contact area) really far. so basically there is a tiny clean part in the center and the edges are all super rough and rusty.
the upgrade really isn't worth it. i have girling 60s with a 23mm MC and 11" rotors on my TDI. the problem is that the booster doesn't seem to keep up, so you need to stomp the pedal to get the bite you want.
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