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.
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 agree that girling 60 are too heavy compared to 54. With good pads 54 offer more than enough stopping power.
I had this retrofit on my Jetta and I was a big fan of it. The unsprung weight complaint I find to be a bit much. As stated above, the weight difference isn't exceptional. The gain here is that you have a greater surface area of clamping force with the addition of an extra caliper piston. Overall, the cost/benefit of this setup is great.
A Mk2 6 line kit will do you just fine here. The Caliper ends up in almost the exact same place as the 9.4 calipers. Ive been runnin Mk2 lines on my 20v car with the Girling 60s for years and theyre not even remotely tight when the car is raised.
Maybe take a look at the Girling 60 calipers and the 11.2 inch rotors from a 'rado g60. Nice large dual piston calipers and 11.2 inch rotors on a mk2 is just about overkill.
I have an 04 W8, ill say this. Get a BBK from Brembo or someone. The front calipers are way to wide and large for what they would do for a smaller car vs the cost to make them work.
Girling 60's if you want 2 pots. Save yourself the head ache and get some wilwoods in the classifieds if you want more then a Girling 54.
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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