As promised I did the driver's side brake duct install today.
As a caveat I'll state the following:
Make no illusions... This install will absolutely rub if you bring the wheel to full lock. I've done a couple 120 degree turns (wheel 1-1/4ish full turns) with no rubbing. However if you sit in a parking lot at full lock driving in a circle you'll destroy the hose.
However, if you track you car I highly recommend it. I haven't tracked it yet with this install but I measured rotors temps when I only had my passenger side on. The rotor temp after very brief spirited low speed driving was 60-100 degrees cooler on the ducted rotor. EVEN if you can't deal with the idea of the hose rubbing you can always install the spindle plate and then run cheap 3.5 inch dryer hose on track day. I can't imagine it rubbing at the track since the steering wheel is never really past 1/2 a turn... unless you're at Monaco and having to deal with the Loews hairpin. But if you're racing you car at Monaco you have no sympathy from me :P
On to the pics, since that's what you're here for.
Picture 1
Get your hub assembly to look like this. Remove wheel, remove caliper, remove rotor, remove hub. There are a ton of write-ups that can get you to this point.
Picture 2
This is the C5 Z06 spindle plate that I started with. You will remove the stock plate that holds the ABS wire and replace it with this plate. (Just loosely zip tie the ABS wire to the end-link when you are done) As you can see, the 3 holes that were drilled in the plate weren't in the right places for the V. Drilling the right holes is a piece of cake. Just place the plate against the hub and mark the holes from behind with a sharpie. The holes don't need to be exactly the right size as long as all 3 hub bolts can get through.
Picture 3
Since the V's brake calipers are infinitely superior to those of the C5 Z06
you need to cut away some of the spindle plate. The Xs are where the caliper bolts would hit the plate if installed like this. (Trust me... I did it on the other side) The line is where I cut.
Picture 4
Any excuse to use your dremel is a good one. If you don't have a dremel then your tool box isn't complete.
Picture 5
With the spindle plate done it's time to run the hose. Step 1, remove the wheel well. There are about 5-6 plastic bolt/pins that need to be removed with a flat head screwdriver.
Picture 6
This is how I attached the 3.5 inch silicone hose to the front stock inlet. 2 hose clamps are probably overkill... but I had them.
Picture 7
This is a very technical move called "squeezing the hose to make it flat". What this accomplishes is getting the hose flatter to avoid rubbing. It's tough to write a walk-through about this since a lot of it is just looking at it and figuring out how much you need to flatten.
This is the part that could be eliminated if someone awesome out there could mold a plastic vent similar to the DRM vette kits. But it's have to be super thin.
Picture 8
Here's the hose thinned down and zip-tied to something back there (I think it was part of the frame. I used 2 x 11 inch zip ties connected together. I suggest you get a bag of 50-100... you can never have too many zip ties.
Picture 9
Wheel well lining reinstalled. Again, this is a part done "by feel" You will have to cut a hole in the liner to allow the hose to pass through. I just used a razor to cut the liner. The goal is to get the liner to reattach in as stock of a position as possible since there is SOOOO little room in the wheel well. This will help eliminate rubbing.
Picture 10
Attach the hose to the spindle plate. Since both the hose and the plate I used are 3.5 inches the hose doesn't want to attach. I just removed about 2-3 inches of the metal wire inside so that I was left with just silicone hose. That stretches better than metal wire. Durrr...
This is just a work in progress. As you all know by now if you've done any sort of non-typical modding, unlike the Vette guys you can't just call up someone and order something off the shelf without having to cut, grind or hack it.
If anyone decides to do this and can suggest something better please let me know. I use my V as a daily driver so I'll be posting how the hoses hold up. My guess is that 3-4 months of daily driving is all they will be able to take due to the random U-turn.
Again, once the spindle plates are installed they are there for good. IF you destroy the hose you can always pick up some cheap dryer hose from Home Depot/Lowes and install it in 15 min per side at the track... at the same time that you're changing your street tires for your R-comps
